Automatic Transaxle Unit (For Sedan) Reassembly

Coat the front differential case and bearing with Toyota Genuine ATF WS or equivalent and install them onto the transaxle case.

Install the transaxle housing with the 14 bolts.

Torque:

Bolt A:

29 N*m{300 kgf*cm, 22 ft.*lbf}

Bolt B:

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

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

SST

09564-32011

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

09554-14010
09950-70010(09951-07100)

Oil seal drive in depth:

1.5 to 2.5 mm (0.059 to 0.098 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:

5.4 to 6.4 mm (0.213 to 0.252 in.)

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

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

SST

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

Install the thrust bearing onto the transaxle housing.

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

SST

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

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

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

Torque:

11 N*m{115 kgf*cm, 8 ft.*lbf}

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

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

SST

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

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

SST

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

Install the counter drive gear bearing onto 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 onto the counter driven gear.

SST

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

NOTICE:

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

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

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

SST

09221-25026(09221-00071)

Standard clearance:

2.5 to 2.6 mm (0.0984 to 0.1023 in.)

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

Coat the parking lock pawl shaft with Toyota Genuine ATF WS or equivalent.

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

NOTICE:

Check that the parking lock pawl moves smoothly.

Install the manual valve lever shaft onto the transaxle case.

NOTICE:

Do not damage the oil seal lip.

Install the parking lock rod onto the manual valve lever.

Coat the manual valve lever sub-assembly with Toyota Genuine ATF WS or equivalent.

Install the manual valve lever and a new manual valve lever spacer onto 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 in 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.

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

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

Torque:

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

Coat 2 new O-rings with Toyota Genuine ATF WS or equivalent, and install them onto No. 2 brake piston.

Coat No. 2 1st and reverse brake piston with Toyota Genuine ATF WS or equivalent, and install it into the transaxle case.

NOTICE:

Do not damage the oil seal lip.

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

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

SST

09387-00070

Using SST and a press, install the counter drive gear onto 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 onto 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

09387-00121

Torque:

280 N*m{2,855 kgf*cm, 207 ft.*lbf}

Using SST and a small 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)

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

SST

09930-00010

Install the 4 plates, 4 discs and flange onto 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.)

NOTICE:

If the clearance is outside the specifications, select a new brake flange.

HINT:

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 onto the planetary gear assembly.

Coat 2 new 2nd brake cylinder O-rings with Toyota Genuine ATF WS or equivalent, and install them into the 2nd brake cylinder.

NOTICE:

Do not damage the O-rings.

Coat the 2nd brake piston with Toyota Genuine ATF WS or equivalent, and install it into the 2nd brake cylinder.

CAUTION:

Do not damage the O-rings when pressing the 2nd brake piston into the 2nd brake cylinder by hand.

Install the piston return spring.

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

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.

Install the outer retainer onto No. 2 1-way clutch.

Install the 1-way clutch and 2nd brake piston assembly onto the rear planetary gear assembly.

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

Install the rear planetary gear assembly onto the transaxle case.

Using a screwdriver, install the snap ring.

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

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

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

Using a screwdriver, install a snap ring onto 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.)

NOTICE:

If the clearance is outside the specifications, select a new brake flange.

HINT:

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 onto the transaxle case.

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

Install 1-way clutch assembly onto the rear planetary sun gear assembly.

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

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

Install the rear planetary sun gear assembly.

Install the thrust bearing onto the rear planetary sun gear.

Install the direct clutch hub.

Install No. 3 thrust bearing race, the thrust needle roller bearing and the C-2 hub thrust bearing race onto the direct clutch hub.

Install the 2 discs, 2 plates and flange onto the transaxle case.

Coat a new O-ring with Toyota Genuine ATF WS or equivalent and install it into the direct clutch drum.

NOTICE:

Do not damage the O-rings.

Coat 2 new O-rings with Toyota Genuine ATF WS or equivalent and install them into the direct clutch piston.

NOTICE:

Do not damage the O-rings.

Coat the direct clutch drum with Toyota Genuine ATF WS or equivalent.

Align the cutout in the intermediate shaft assembly with the matchmark on the direct clutch drum and install the direct clutch drum onto the intermediate shaft assembly.

NOTICE:

Do not damage the O-ring or the lip of the clutch drum.

Coat the direct clutch piston with Toyota Genuine ATF WS or equivalent and install it into the intermediate shaft.

NOTICE:

Do not damage the O-ring or the direct clutch piston.

Install the direct clutch return spring onto the direct clutch piston.

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

SST

09387-00020

Using snap ring pliers, install the snap ring into the direct clutch drum.

NOTICE:

1. Stop pressing the press when the spring seat is lowered to 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from deforming.
   
2. Do not expand the snap ring excessively.
   

Coat the 3 rear clutch flanges, 3 discs and direct clutch flange with Toyota Genuine ATF WS or equivalent and install them onto the intermediate shaft.

Install the snap ring into the intermediate shaft.

Coat the 2 plates, 2 discs and flange with Toyota Genuine ATF WS or equivalent, and install them onto the intermediate shaft.

Install the snap ring into the intermediate shaft.

Install the intermediate shaft and thrust needle roller bearing onto the transaxle rear cover.

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 brake flange.

HINT:

There are 4 different flange thicknesses.

Install the intermediate shaft and thrust needle roller bearing onto the transaxle rear cover.

Using a dial indicator and measuring terminal (SST), measure the forward 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 brake flange.

HINT:

There are 4 different flange thicknesses.

Install the intermediate shaft assembly onto 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.)

NOTICE:

If the clearance is outside the specifications, select a new brake flange.

HINT:

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 onto the intermediate shaft.

Install the transaxle rear cover with the 11 bolts.

Torque:

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

Using a dial indicator, measure the clearance of the intermediate shaft.

Standard clearance:

0.204 to 0.966 mm (0.008 to 0.038 in.)

Remove the 11 bolts and the transaxle rear cover.

Install 4 new gaskets onto the transaxle case.

Coat a new needle roller bearing with Toyota Genuine ATF WS or equivalent.

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

SST

09950-60010(09951-00190,09952-06010)
09950-70010(09951-07100)

Standard clearance:

25.2 mm (0.992 in.)

Compress the oil seal ring from both sides to reduce dimension A.

Dimension A:

5.0 mm (0.197 in.)

Coat the oil seal ring with Toyota Genuine ATF WS or equivalent and install it onto the rear transaxle cover.

Coat 2 new O-rings with Toyota Genuine ATF WS or equivalent and install them into the 2nd coast and overdrive brake piston.

NOTICE:

Do not damage the O-rings.

Coat the piston with Toyota Genuine ATF WS or equivalent and install it into the transaxle rear cover.

NOTICE:

Do not damage the O-rings.

Using SST and a press, install the overdrive brake return spring and snap ring onto the transaxle rear cover.

SST

09387-00070

NOTICE:

1. Stop pressing the press when the spring sheet is lowered to 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, to prevent the spring sheet from deforming.
   
2. Do not expand the snap ring excessively.
   

Coat 4 new O-rings with Toyota Genuine ATF WS or equivalent, and install them into the 4 rear transaxle cover plugs.

Install the 4 rear transaxle cover plugs into the rear transaxle cover.

Torque:

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

NOTICE:

Do not damage the O-rings.

Apply FIPG to the transaxle case.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent

Install the rear transaxle cover with the 11 bolts.

Torque:

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

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

Install the bearing onto the forward clutch hub.

Coat a new input shaft oil seal ring with Toyota Genuine ATF WS or equivalent, and install it into the input shaft.

Coat a new clutch piston O-ring with Toyota Genuine ATF WS or equivalent, and install it into the forward clutch piston.

Install the forward clutch piston into the input shaft.

NOTICE:

Do not damage the O-ring.

Install the return spring and clutch balancer into the input shaft.

Using SST, a press and snap ring pliers, install the snap ring onto the input shaft.

SST

09320-89010

Install the 4 plates, 4 discs and flange.

Using a screwdriver, install the snap ring into the input shaft.

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 (0.05535 to 0.07110 in.)

NOTICE:

If the clearance is outside the specifications, select a new brake flange.

HINT:

There are 4 different flange thicknesses.

Install the bearing onto the input shaft assembly.

Install the input shaft assembly onto the transaxle case.

Install 2 new gaskets onto the transaxle case.

Install the differential gear assembly onto the transaxle case.

Install the oil pump with the 7 bolts.

Torque:

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

Make sure that the input shaft turns smoothly.

Measure the end play in the axial direction.

End play:

0.37 to 1.29 mm (0.0146 to 0.0508 in.)

Apply FIPG to the transaxle case.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent

Install the transaxle housing with the 14 bolts.

Torque:

Bolt A:

29 N*m{300 kgf*cm, 22 ft.*lbf}

Bolt B:

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

Coat 2 new O-rings with Toyota Genuine ATF WS or equivalent and install them onto the C-2 accumulator piston.

NOTICE:

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 Toyota Genuine ATF WS or equivalent and install them onto the C-3 accumulator piston.

NOTICE:

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	80.20 (3.1575) 18.70 (0.7362)	Blue

Coat 2 new O-rings with Toyota Genuine ATF WS or equivalent and install them onto the B-2 accumulator piston.

NOTICE:

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)	Green

Install the spring and check ball body.

Install a new brake drum gasket.

Coat a new transaxle case gasket with Toyota Genuine ATF WS or equivalent, and install it onto the transaxle case.

Coat a new transaxle case 2nd brake gasket with Toyota Genuine ATF WS or equivalent, and install it onto the transaxle case.

Coat a new O-ring with Toyota Genuine ATF WS or equivalent, and install it onto the transmission wire.

Insert the transmission wire into the transaxle.

Install the transmission wire with the bolt.

Torque:

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

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

Provisionally 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.)

Provisionally 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.

Torque:

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

Connect the 5 solenoid connectors.

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

Torque:

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

Bolt length:

55 mm (2.17 in.)

Coat a new O-ring with Toyota Genuine ATF WS or equivalent, and install it into the oil strainer.

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

Torque:

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

Install the 2 magnets onto the oil pan.

Install a new oil pan gasket onto the oil pan.

Install the oil pan with the 19 bolts.

Torque:

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

Install the breather plug hose onto the transaxle case.

Coat 5 new O-rings with Toyota Genuine ATF WS or equivalent, and install them onto the screw plugs.

Install the 4 screw plugs onto the transaxle housing and transaxle case.

Torque:

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

Install the screw plug onto the transaxle case.

Torque:

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

Coat 2 new O-rings with Toyota Genuine ATF WS or equivalent, and install them into the 2 oil cooler tube unions.

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

Torque:

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

Coat a new O-ring with Toyota Genuine ATF WS or equivalent, and install it into the transmission revolution sensor.

Install the transmission revolution sensor onto the transaxle case with the bolt.

Torque:

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

Install the park/neutral position switch assembly onto the manual transaxle.

Provisionally install the 2 bolts.

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

Torque:

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

Provisionally 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.

Torque:

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

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

Install the control shaft lever with the nut and washer.

Torque:

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

Coat a new O-ring with Toyota Genuine ATF WS or equivalent and install it into the speedometer sensor.

Install the driven gear into the speedometer sensor with the clip.

Install the speedometer sensor onto the transaxle housing.