Automatic Transaxle Unit Reassembly

Check each 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.

Torque:

Bolt A:

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

Bolt B:

22 N*m{224 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 (0.1083)
09	2.30 (0.0906)	19	2.80 (0.1102)
10	2.35 (0.0925)

Coat the lip of a new No. 1 transaxle case oil seal with MP grease.

Using SST and a hammer, drive in the No. 1 transaxle case oil seal.

SST

09387-00010
09950-70010(09951-07100)

Oil seal driven in depth:

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

Coat the lip of a new No. 2 transaxle case oil seal with MP grease.

Using SST and a hammer, drive in the No. 2 transaxle case oil seal.

SST

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

Oil seal driven in depth:

2.2 to 3.2 mm (0.0866 to 0.126 in.)

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

Using SST and a hammer, install a new 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.

Torque:

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

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 inner race LH and angular ball 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 manual valve lever shaft oil seal with MP grease.

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

SST

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

Oil seal driven in depth:

-0.5 to 0.5 mm (-0.0197 to 0.0197 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)

NOTICE:

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 0.137 in.)

Install the counter driven gear and drive pinion thrust bearing LH 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.

NOTICE:

Check that the parking lock pawl moves smoothly.

Install the manual valve lever shaft to the transaxle case.

NOTICE:

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.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Coat 2 new No. 2 1st and reverse brake piston O-rings with ATF, and install them to the No. 2 1st and reverse brake piston.

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

NOTICE:

Do not damage the O-ring.

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

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)

Secure 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{2855 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 (2.0 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

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 1st and reverse brake clearance while pressing the discs and plates from the rear side.

SST

09350-36010(09350-06110)

Pack clearance:

0.81 to 1.20 mm (0.0318 to 0.0472 in.)

NOTICE:

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

HINT:

There are 4 different thicknesses of flanges available.

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 (392 kPa, 4.0 kgf/cm², 57 psi) is applied to the oil hole.

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

Coat 2 new 2nd brake cylinder O-rings with ATF, and install them into the 2nd brake cylinder.

NOTICE:

Do not damage the O-rings.

Coat the 2nd brake piston with ATF, 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.

SST

09387-00060

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 race retainer to the No. 2 one-way clutch.

Install the No. 2 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, 3 No. 1 2nd brake flanges and 2 2nd brake flanges to the transaxle case.

Using a screwdriver, install the 2 snap rings to the transaxle case.

Using a dial indicator, measure the 2nd brake pack clearance while applying and releasing compressed air (392 to 785 kPa, 4.0 to 8.0 kgf/cm², 57 to 114 psi).

Pack clearance:

0.85 to 1.24 mm (0.0334 to 0.0488 in.)

NOTICE:

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

HINT:

There are 4 different thicknesses of flanges available.

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)

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 needle roller bearing and the washer to the rear planetary sun gear.

Install the rear planetary sun gear assembly.

Install the rear No. 2 planetary sun gear thrust needle roller 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.

Measure the flange thickness. (Dimension A)

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

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

NOTICE:

Do not damage the O-ring.

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

NOTICE:

Do not damage the O-rings.

Coat the direct clutch drum with ATF.

Align a cutout on the intermediate shaft assembly with the matchmark on the direct clutch drum and install the direct clutch drum to the intermediate shaft assembly.

NOTICE:

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

Coat the direct clutch piston with ATF and install it to 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 to the direct 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 to prevent the spring seat from being deformed.
   
2. Do not expand the snap ring excessively.
   

Coat the 3 rear clutch flanges, 3 discs and direct clutch flange with ATF and install them to the intermediate shaft.

Install the snap ring to the intermediate shaft.

Coat the 3 plates, 3 discs and flange with ATF, and install them to the intermediate shaft.

Install the snap ring to the intermediate shaft.

Install the intermediate shaft and thrust needle roller bearing to the rear transaxle 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:

0.62 to 1.16 mm (0.0244 to 0.0456 in.)

NOTICE:

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

HINT:

There are 4 different thicknesses of flanges available.

Flange Thickness:

No.	Thickness (mm (in.))	No.	Thickness (mm (in.))
-	3.0 (0.118)	2	3.4 (0.134)
1	3.2 (0.126)	3	3.6 (0.142)

Install the intermediate shaft and thrust needle roller bearing to 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 compressed air is applied.

Therefore, while performing the check, press on the input shaft of the direct and reverse clutch using a press 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 not within the specified range, select a new clutch flange.

HINT:

There are 4 different flange thicknesses.

Flange Thickness:

No.	Thickness (mm (in.))	No.	Thickness (mm (in.))
-	3.0 (0.118)	2	3.4 (0.134)
1	3.2 (0.126)	3	3.6 (0.142)

Install the intermediate shaft assembly to the transaxle case.

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 the straightedge using a vernier caliper. (Dimension B)

As shown in the illustration, place a straightedge on the overdrive brake piston and measure the distance between the transaxle rear cover and straightedge using a vernier caliper. (Dimension C)
Calculate the piston stroke value using the following formula.

Formula:

(Dimension A + Dimension B) - Dimension C

Pack clearance:

2.10 to 2.49 mm (0.0826 to 0.0980 in.)

NOTICE:

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

HINT:

There are 4 different thicknesses of flanges available.

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 rear transaxle cover with the 11 bolts.

Torque:

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

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

End play:

0.21 to 0.96 mm (0.00826 to 0.0377 in.)

HINT:

There are 2 different thicknesses of trust needle roller bearings available.

Remove the 11 bolts and the rear transaxle cover.

Install 4 new gaskets to the transaxle case.

Coat a new needle roller bearing with ATF.

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:

25.1 mm (0.988 in.)

Compress the 3 oil seal rings from both sides to reduce dimension A.

Dimension A:

5.0 mm (0.197 in.)

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

Coat 2 new O-rings with ATF and install them to the 2nd coast and overdrive brake piston.

NOTICE:

Do not damage the O-rings.

Coat the piston with ATF and install it to the rear transaxle cover.

NOTICE:

Do not damage the O-rings.

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

SST

09387-00070

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.
   

Coat 4 new O-rings with ATF, and install them to the 4 rear transaxle cover plugs.

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

Torque:

7.4 N*m{76 kgf*cm, 66 in.*lbf}

NOTICE:

Do not damage the O-rings.

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.

Torque:

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

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

Install the bearing to the forward clutch hub.

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

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

Install the forward clutch piston to the input shaft.

NOTICE:

Do not damage the O-ring.

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

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

SST

09320-89010

Install the 4 plates, 4 discs and flange.

Using a screwdriver, install the snap ring to 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:

1.41 to 1.80 mm (0.0555 to 0.0708 in.)

NOTICE:

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

HINT:

There are 4 different thicknesses of flanges available.

Flange Thickness:

No.	Thickness (mm (in.))	No.	Thickness (mm (in.))
-	3.0 (0.118)	2	3.4 (0.134)
1	3.2 (0.126)	3	3.6 (0.142)

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.

Torque:

22 N*m{224 kgf*cm, 16 ft.*lbf}

Make sure that the input shaft turns smoothly.

Measure the end play in the axial direction.

End play:

0.38 to 1.29 mm (0.0149 to 0.0507 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.

Torque:

Bolt A:

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

Bolt B:

22 N*m{224 kgf*cm, 16 ft.*lbf}

Coat 2 new O-rings with ATF and install them to 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	66.20 to 67.60 (2.606 to 2.661) 17.20 (0.677)	-

Coat 2 new O-rings with ATF and install them to 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	87.30 (3.437) 18.70 (0.736)	Orange

Coat 2 new O-rings with ATF and install them to 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 (2.633) 15.50 (0.610)	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 into the transmission wire.

Insert the transmission wire to 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.

Temporarily install the valve body with the 13 bolts.

Bolt length:

Bolt A: 32 mm (1.26 in.)
Bolt B: 22 mm (0.866 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 (0.551 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{112 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{112 kgf*cm, 8 ft.*lbf}

Bolt length:

55 mm (2.17 in.)

Coat a new gasket with ATF, and install it to the oil strainer.

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

Torque:

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

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.

Torque:

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

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 5 No. 1 transaxle case plugs.

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

Torque:

7.4 N*m{76 kgf*cm, 66 in.*lbf}

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

Torque:

7.4 N*m{76 kgf*cm, 66 in.*lbf}

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.

Torque:

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

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.

Torque:

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

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.

Torque:

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

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.

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{133 kgf*cm, 10 ft.*lbf}

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.

Torque:

5.5 N*m{56 kgf*cm, 49 in.*lbf}