Automatic Transaxle Unit: Reassembly

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

   Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

   NOTE: Make sure to insert the pipe to the stopper.

Fig 2: Identifying Differential Gear Lube Apply Tube

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1. Install 2 new O-rings to the 2 transaxle case No. 1 plugs.
2. Install the 2 transaxle case No. 1 plugs to the transaxle rear cover.

   Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

Fig 3: Identifying Transaxle Case No. 1 Plug

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

Fig 4: Installing Underdrive Output Shaft Oil Seal Ring

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1. Coat the underdrive cylindrical roller bearing with ATF.
2. Using SST and a press, install the underdrive cylindrical roller bearing.

   SST 09950-60020 (09951-00810), 09950-70010 (09951-07100) 

   NOTE: Do not apply excessive pressure to the bearing.

Fig 5: Identifying Underdrive Cylindrical Roller Bearing

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

   • Do not expand the end gap of the oil seal ring too much.
   • Fix the hooks firmly. Confirm that the oil seal ring rotates freely in its groove.

Fig 6: Installing Underdrive Clutch Drum Oil Seal Ring

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

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

   NOTE: Clean SST to remove deposited oil, before wrapping vinyl tape.
   Fig 7: Wrapping Vinyl Tape Around SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the needle roller bearing with ATF.
3. Using SST and a press, install the needle-roller bearing to the transaxle case.

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

   NOTE: When the wrapped vinyl tape contacts the transaxle case, stop press-fitting.

Fig 8: Installing Needle-Roller Bearing To Transaxle Case

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

   • Make sure that the O-rings are not twisted or pinched when they are installed.
   • Apply sufficient ATF to the O-ring before installing.
   Fig 9: Installing O-Rings With ATF

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the underdrive brake piston with ATF.
3. Install the underdrive brake piston to the transaxle case.
   NOTE: Be careful not to damage the O-ring.

Fig 10: Installing Underdrive Brake Piston To Transaxle Case

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

   SST 09387-00020 

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

   • Stop the press when the spring seat is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, to prevent the spring seat from being deformed.
   • Do not expand the snap ring excessively.
   • Installing the spring sub-assembly, check that all of the springs are fit in the piston correctly.
   • The snap ring should be fully engaged in the groove of the transaxle case.

Fig 11: Installing Underdrive Brake Return Spring Sub-Assembly

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1. Coat the counter drive gear bearing with ATF.
2. Using SST and a press, install the bearing outer race.

   SST 09950-60020 (09951-01030), 09950-70010 (09951-07150), 09649-17010 

   NOTE:

   • Do not apply excessive pressure to the bearing.
   • Press-fit the bearing outer race until it contacts the transaxle case.
   Fig 12: Installing Bearing Outer Race

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3. Using a snap ring expander, install the snap ring.
   NOTE: The white mark side of the snap ring should face upward.

Fig 13: Installing Snap Ring

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1. Coat the couter drive gear with ATF.
2. Using SST and a press, install the tapered roller bearing to the counter drive gear.

   SST 09950-70010 (09951-07150), 09649-17010 

   NOTE: Do not apply excessive pressure to the bearing.
   Fig 14: Installing Tapered Roller Bearing To Counter Drive Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, install the counter drive gear and bearing to the transaxle case.

   SST 09950-70010 (09951-07150), 09223-15030, 09527-17011, 09950-60020 (09951-00750) 

   NOTE: Do not apply excessive pressure to the counter drive gear.

Fig 15: Installing Counter Drive Gear And Bearing To Transaxle Case

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1. Coat 2 new O-rings with ATF.
2. Install the 2 O-rings to the 1st and reverse brake piston.
   NOTE:

   • Make sure that the O-rings are not twisted or pinched when they are installed.
   • Apply sufficient ATF to the O-ring prior to assembling.
   Fig 16: Installing O-Rings To 1st And Reverse Brake Piston

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the 1st and reverse brake piston with ATF, and install it to the transaxle case.
   NOTE: Be careful not to damage the O-ring.

Fig 17: Installing 1st And Reverse Brake Piston With ATF

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

   SST 09387-00070 

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

   • Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, preventing the spring seat from being deformed.
   • Do not expand the snap ring excessively.
   • Installing the spring sub-assembly, check that all of the springs are fit in the piston correctly.
   • The snap ring should be fully engaged in the groove of the cylinder.
   • Fix the snap ring to the inside of the claw of the spring seat firmly.

Fig 18: Installing 1st And Reverse Brake Return Spring Sub-Assembly

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1. Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.
   NOTE: Confirm that the snap ring is engaged in the groove of the brake hub correctly.

Fig 19: Installing Front Planetary Ring Gear And Snap Ring To Brake Hub

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1. Install the front planetary gear assembly to the brake hub.
   Fig 20: Installing Front Planetary Gear Assembly To Brake Hub

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

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

   NOTE:

   • Do not apply excessive pressure to the planetary gear assembly.
   • Press the inner race of LH tapered roller bearing, counter gear and front planetary gear assembly to the position where no preload should be applied to one pair of tapered roller bearings (left and right).
   Fig 21: Pressing-Fit Front Planetary Gear Assembly

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3. Install a new washer as shown in the illustration.
   Fig 22: Installing Washer

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4. Using SST, install the nut.

   SST 09387-00030, 09387-00080 

   Torque: 280 N*m (3,355 kgf*cm, 207 ft.*lbf) 

   NOTE: Assemble the washer after pressing each part, then tighten the nut to the minimum tightening torque.
   Fig 23: Installing Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm. When the measured value is not as specified, gradually tighten the nut until it reaches the specified value.

   SST 09387-00080 

   Standard: 

   Turning torque at 60 rpm 

   Bearing: 

   New Bearing: 0.51 to 1.02 N*m (5.1 to 10.0 kgf*cm, 4.4 to 8.7 in.*lbf) 

   Used Bearing: 0.26 to 0.51 N*m (2.7 to 5.2 kgf*cm, 2.3 to 4.5 in.*lbf) 

   HINT:

   Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).

   Fig 24: Measuring Turning Torque Of Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Tighten the nut gradually until the specified turning torque of tapered roller bearing is measured.

   Torque: 350 N*m (3,569 kgf*cm, 258 ft.*lbf) 

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

Fig 25: Staking Front Lock Washer

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1. Coat the 2 thrust bearings with ATF.
   Fig 26: Coating Thrust Bearing With ATF

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2. Install the 2 thrust bearings, the bearing race and the input sun gear to the front planetary gear assembly.
   NOTE:

   • Install the bearing race on the side of the front planetary carrier. Be careful about the direction of the race.
   • Installing thrust bearing and front sun gears, be careful about the direction of the parts.
   • Install the bearing race on the side of the front sun gear. Be careful about the direction of the race.
   • Install the thrust bearing and the race after holding the parts on the input sun gear by applying grease. Make sure that the assembling order is correct.

Thrust bearing and bearing race diameter: mm (in.) 

1. Install the rear planetary gear assembly to the rear planetary ring gear.
   Fig 27: Installing Rear Planetary Gear Assembly To Rear Planetary Ring Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the snap ring.
   NOTE: Confirm that the snap ring is fixed in the groove of the 1st and reverse brake hub correctly.

Fig 28: Installing Snap Ring

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1. Coat the 6 discs with ATF.
2. Install the 7 plates and 6 discs.
   NOTE: Make sure that the plates, discs, and flange are installed as shown in the illustration.

Fig 29: Installing 1st And Reverse Brake Clutch Disc

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1. Using vernier calipers, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case (Dimension A).
   Fig 30: Measuring Distance Between Disc Surface And Contact Surface

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Select an appropriate flange so that the pack clearance will meet the specified value.

   Pack clearance: 1.16 to 1.35 mm (0.0457 to 0.0531 in.) 

   HINT:

   Piston stroke = Dimension A - Flange thickness

   Flange thickness: mm (in.) 

   PACK CLEARANCE OF FIRST AND REVERSE BRAKE
   
   

   Mark	Thickness	Mark	Thickness
   1	1.8 (0.071)	5	2.2 (0.087)
   2	1.9 (0.075)	6	2.3 (0.091)
   3	2.0 (0.079)	7	2.4 (0.094)
   4	2.1 (0.083)	8	2.5 (0.098)

3. Install the flange.

Fig 31: Installing Flange

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1. Install the second brake piston assembly to the transaxle case.
   Fig 32: Installing Second Brake Piston Assembly To Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the snap ring and measure the inside diameter.

   Inside diameter: Greater than 167 mm (6.57 in.) 

   NOTE:

   • Make sure that the taper snap ring is installed in the correct direction.
   • When the diameter does not meet the specified value, replace the snap ring with a new one.
   • After installing, confirm that there is no clearance between the 2nd brake cylinder and the fitting surface of the cylinder in the transaxle case.

Fig 33: Installing Snap Ring

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1. Install the 1-way clutch sleeve outer to the 2nd brake cylinder assembly.
   NOTE: Make sure that the outer sleeve is installed in the correct direction.

Fig 34: Installing 1-Way Clutch Sleeve Outer To 2nd Brake Cylinder Assembly

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1. Install the 1-way clutch inner race to the 1-way clutch.
   NOTE:

   • Make sure that the inner race is installed in the correct direction.
   • Confirm that the discrimination mark is visible.
   Fig 35: Installing 1-Way Clutch Inner Race To 1-Way Clutch

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the rotating direction of 1-way clutch for the lock or free operation as shown in the illustration.
   Fig 36: Checking Rotating Direction Of 1-Way Clutch For Lock Or Free Operation

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3. Install the 1-way clutch and thrust needle roller bearing to the 1-way clutch sleeve outer.

Bearing diameter: mm (in.) 

Fig 37: Installing 1-Way Clutch And Thrust Needle Roller Bearing To 1-Way Clutch Sleeve Outer

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1. Coat the planetary carrier thrust washer No. 1 with yellow petrolatum, and install the washer onto the planetary sun gear assembly.
   NOTE: After installing, confirm that the projection should be fixed firmly in the hole of the planetary sun gear assembly.

Fig 38: Installing Planetary Carrier Thrust Washer No. 1

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1. Coat the planetary carrier thrust washer No. 2 with yellow petrolatum, and install the washer onto the rear planetary sun gear.
   Fig 39: Installing Planetary Carrier Thrust Washer No. 2 Onto Rear Planetary Sun Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the bearing with yellow petrolatum, and install the bearing onto the rear planetary sun gear.

   Bearing diameter: mm (in.) 

   BEARING DIAMETER
   
   

   	Inside	Outside
   Race, A	33.0 (1.299)	45.4 (1.787)
   Bearing, B	31.85 (1.254)	45.2 (1.78)

   Fig 40: Installing Bearing Onto Rear Planetary Sun Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the rear planetary sun gear assembly to the rear planetary gear.
   NOTE: Installing the rear planetary sun gear assembly, make sure that the B1 discs are engaged.

Fig 41: Installing Rear Planetary Sun Gear Assembly To Rear Planetary Gear

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1. Coat the 4 discs with ATF.
2. Install the 4 discs and 5 plates to the transaxle case.
3. Temporarily install the snap ring.

Fig 42: Installing Discs And Plates To Transaxle Case

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1. Using a vernier calipers, measure the distance between the disc surface and snap ring surface (Dimension B).
   Fig 43: Measuring Distance Between Disc Surface And Snap Ring Surface (Dimension B)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Select an appropriate flange so that the pack clearance will meet the specified value.

   Clearance: 0.62 to 0.91 mm (0.0244 to 0.0358 in.) 

   HINT:

   Piston stroke = Dimension B - Flange thickness - Snap ring thickness 1.6 mm (0.063 in.)

   Flange thickness: mm (in.) 

   PACK CLEARANCE OF 2ND BRAKE
   
   

   Mark	Thickness	Mark	Thickness
   1	3.0 (0.118)	5	3.4 (0.134)
   2	3.1 (0.122)	6	3.5 (0.138)
   3	3.2 (0.126)	7	3.6 (0.142)
   4	3.3 (0.130)	8	-

3. Temporarily remove the snap ring, attach the selected flange and reinstall the snap ring.
   NOTE: Secure the snap ring so that the ends visible through the groove of the transaxle case.

Fig 44: Removing Snap Ring

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1. Install the direct clutch hub to the planetary gear assembly.
   NOTE: Be careful not to damage the bushing inside the overdrive clutch hub during installation.
   Fig 45: Installing Bearing Race And Thrust Bearing To Direct Clutch Hub

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the thrust bearing with ATF.
3. Install the bearing race and the thrust bearing to the direct clutch hub.
   NOTE: Be careful not to drop the bearing when it is installed.

Bearing and race diameter: mm (in.) 

1. Coat the thrust bearing with ATF.
2. Install the direct clutch assembly and thrust bearing to the rear planetary sun gear assembly.
   NOTE: The disc in the direct clutch should completely match with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed.
   Fig 46: Installing Direct Clutch Assembly And Thrust Bearing To Rear Planetary Sun Gear Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Clean the connecting part of the transaxle case and the rear cover.
4. 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 vernier calipers (Dimension C).
   Fig 47: Measuring Distance Between Transaxle Case And Straightedge

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5. Using vernier calipers and a straightedge, measure the dimension shown in the illustration.
   Fig 48: Measuring Dimension Using Vernier Calipers And Straightedge

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install the selected bearing.

   End play: 0.244 to 0.901 mm (0.0096 to 0.0355 in.) 

   NOTE: Make sure that the no-colored race side is facing the direct clutch assembly.

   HINT:

   End play = Dimension D - Dimension C

Bearing thickness and diameter: mm (in.) 

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

Fig 49: Installing Governor Apply Gaskets To Transaxle Case

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1. Install the clamp to the brake apply tube.
   NOTE: 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.
2. Install the clutch apply tube.
   Fig 50: Installing Clutch Apply Tube

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the brake apply tube and a bolt to the transaxle case.

   Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

   NOTE: The tube should be securely inserted until it reaches the stopper.

Fig 51: Installing Brake And Clutch Apply Tube

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

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

   Press fit depth: 20.55 to 21.25 mm (0.8091 to 0.8366 in.) 

   NOTE:

   • The engraved mark side of the bearing should face upward.
   • Repeat the press fit until the specified value is obtained.
2. Coat a needle roller bearing with ATF.

Fig 52: Installing Needle Roller Bearing With ATF

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1. Coat 3 new rear clutch oil seal rings with ATF, install them to the transaxle rear cover.
   NOTE: The snap ring should be fully engaged in the groove of the drum.

Fig 53: Installing Rear Clutch Oil Seal Rings With ATF

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1. Coat 4 new O-rings with ATF.
2. Install the 4 O-rings to the 4 transaxle case No. 1 plugs.
3. Install the 4 transaxle case No. 1 plugs to the transaxle rear cover.

   Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

Fig 54: Installing Transaxle Case No. 1 Plug

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1. Remove any packing material and be careful not to spill oil on the contact surfaces of the transaxle rear cover or the transaxle case.
2. Apply FIPG to the cover.

   FIPG: 

   Part No. 08826-00090, THREE BOND 1281 or equivalent. 

   NOTE: Make sure that the FIPG is applied in a bead (section diameter: diameter 1.2) so that the entire sealing surface will be evenly sealed. The FIPG should also protrude slightly from the flange after the assembly of the parts has been completed.
   Fig 55: Identifying FIPG

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3. Apply liquid sealer to the "A" bolt threads.

   Sealant: 

   Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent. 

4. 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) 

Fig 56: Installing Transaxle Rear Cover Sub-Assembly Bolts

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1. Coat the 4 discs with ATF.
   Fig 57: Coating Underdrive Clutch Disc No. 2 With ATF

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2. Install the 4 discs, 4 plates and flange to the transaxle case.
   NOTE: Be careful about the order of discs, plate and flange assembly.
3. Using a screwdriver, install the snap ring.
   NOTE: The snap ring should be fully engaged in the groove of the drum.
   Fig 58: Installing Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a dial indicator, measure the underdrive brake 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.) 

   HINT:

   Select an appropriate flange from the table below so that it will meet the specified value.

   Flange thickness: mm (in.) 

   PACK CLEARANCE OF UNDERDRIVE BRAKE
   
   

   Mark	Thickness	Mark	Thickness
   1	3.0 (0.118)	4	3.1 (0.122)
   2	3.2 (0.126)	5	3.3 (0.130)
   3	3.4 (0.134)	-	-

2. Temporarily remove the snap ring and attach it to the flange.
3. Reinstall the snap ring.

Fig 59: Measuring Underdrive Brake Pack Clearance

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1. Install the underdrive clutch assembly to the 1-way clutch.
2. Rotate the underdrive clutch assembly to check the rotating direction for the lock or free operation.

Fig 60: Installing Underdrive Clutch Assembly To 1-Way Clutch

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1. Install the outer race retainer to the 1-way clutch.
   NOTE: Fix the outer race retainer to the external tooth of the 1-way clutch firmly.
   Fig 61: Installing Outer Race Retainer To 1-Way Clutch

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 1-way clutch to the transaxle case.
   NOTE: Make sure that the mark on the 1-way clutch outer race is visible.
   Fig 62: Installing 1-Way Clutch To Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, install the snap ring to the transaxle case.
   NOTE: The snap ring should be fixed fully engaged in the groove of the transaxle case.

Fig 63: Installing Snap Ring To Transaxle Case

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1. Coat the bearing and bearing race with petroleum jelly, install them onto the underdrive clutch.

   Bearing and bearing race diameter: mm (in.) 

   BEARING AND BEARING RACE DIAMETER
   
   

   	Inside	Outside
   Bearing	37.73 (1.4854)	58.0 (2.2835)
   Race	29.9 (1.1772)	55.5 (2.185)

   Fig 64: Installing Bearing And Bearing Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the underdrive clutch assembly to the transaxle case.
   NOTE: Do not damage the oil seal when installing the underdrive clutch drum sub-assembly.

1. Install the pawl pin and spring to the parking lock pawl.
   Fig 65: Installing Pawl Pin And Spring To Parking Lock Pawl

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Temporarily install the parking lock pawl, shaft and spring to the transaxle case, as shown in the illustration.

Fig 66: Installing Parking Lock Pawl, Shaft And Spring To Transaxle Case

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1. Install the underdrive planetary gear assembly to the transaxle case.
   NOTE: Fully engage all the discs of underdrive clutch and hub splines of the underdrive planetary gear assembly and install them securely.
   Fig 67: Installing Underdrive Planetary Gear Assembly To Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the parking lock pawl shaft.
   Fig 68: Installing Parking Lock Pawl Shaft

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3. Install the pawl shaft clamp with the bolt.

   Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

   Fig 69: Installing Pawl Shaft Clamp With Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a straightedge and vernier calipers as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and the contact surface of the transaxle case and housing (Dimension E).
   NOTE: Record dimension E for the following process.
   Fig 70: Measuring Gap Between Top Of Differential Drive Pinion

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5. As shown in the illustration, measure the 2 places of the transaxle housing, and calculate dimension F using the formula below.
   NOTE: Record dimension F for the following process.

   HINT:

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

Fig 71: Measuring Places Of Transaxle Housing

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

   Bearing race diameter: mm (in.) 

   BEARING RACE DIAMETER
   
   

   	Inside	Outside
   Bearing race	39.5 (1.555)	45.8 (1.803)

   Fig 72: Installing Thrust Bearing Race

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

   Thrust bearing and race diameter: mm (in.) 

   THRUST BEARING AND RACE DIAMETER
   
   

   	Inside	Outside
   Thrust Bearing	36.4 (1.433)	52.2 (2.055)

3. Coat the needle roller bearing with ATF.
   Fig 73: Installing Thrust Needle Roller Bearing And Race

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

   Bearing diameter: mm (in.) 

   BEARING DIAMETER
   
   

   	Inside	Outside
   Bearing	23.6 (0.929)	44 (1.732)

5. Install the multiple clutch hub to the transaxle case.

Fig 74: Installing Needle Roller Bearing To Multiple Clutch Hub

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1. Coat the thrust needle roller bearing with ATF.
2. Install the thrust needle roller bearing to the forward clutch.

   Thrust bearing diameter: mm (in.) 

   THRUST BEARING DIAMETER
   
   

   	Inside	Outside
   Thrust Bearing	33.58 (1.3220)	51.9 (2.043)

   NOTE: Install the thrust bearing properly so that the no colored race or blue ink jet race will be visible.
   Fig 75: Installing Thrust Needle Roller Bearing To Forward Clutch

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3. Install the forward clutch to the forward clutch assembly.
   NOTE:

   • Align the splines of all discs in the forward clutch with those of multiple clutch hub to install them securely.
   • Be careful not to damage the bushing inside of the forward clutch hub during installation.

Fig 76: Installing Forward Clutch To Forward Clutch Assembly

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1. Install 2 new overdrive brake gaskets.

Fig 77: Installing Overdrive Brake Gaskets

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1. Install the differential gear assembly to the transaxle case.

Fig 78: Installing Differential Gear Assembly To Transaxle Case

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

Fig 79: Installing Thrust Bearing Underdrive Race

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1. Coat the thrust needle roller bearing with ATF.
2. Calculate the end play value using the following formula and values of Dimension E and F that are measured when installing the cylindrical roller bearing and underdrive planetary gear. Select an appropriate underdrive planetary gear thrust bearing race No. 2 which satisfies the specified end play value, and install the selected bearing race.

   End play: 

   0.498 to 0.993 mm (0.01961 to 0.03909 in.) 

   HINT:

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

Race thickness: mm (in.) 

Bearing and bearing race diameter: mm (in.) 

Fig 80: Installing Thrust Needle Roller Bearing With ATF

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Torque: 22 N*m (226 kgf*cm, 16 ft.*lbf) 

   Fig 81: Installing Oil Pump To Transaxle Case With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the O-ring of oil pump with ATF.
   NOTE: Confirm that the input shaft rotates smoothly with the manual operation after installing the oil pump.

Fig 82: Installing O-Ring Of Oil Pump With ATF

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove any packing material and be careful not to spill oil on the contact surface of the transaxle case or transaxle housing.
2. Apply FIPG to the transaxle case.

   FIPG: 

   Part No. 08826-00090, THREE BOND 1281 or equivalent 

   Fig 83: Applying FIPG To Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the transaxle housing and 16 bolts to the transaxle case.

   Torque 

   Bolt A: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

   Bolt B: 33 N*m (337 kgf*cm, 24 ft.*lbf) 

   Bolt C: 29 N*m (295 kgf*cm, 21 ft.*lbf) 

   Bolt D: 22 N*m (226 kgf*cm, 16 ft.*lbf) 

   HINT:

   Apply seal packing or equivalent to bolts A and D.

   Seal packing: 

   THREE BOND 2403 or equivalent 

   Bolt length 

   Bolt A: 50 mm (1.969 in.) 

   Bolt B: 50 mm (1.969 in.) 

   Bolt C: 42 mm (1.654 in.) 

   Bolt D: 72 mm (2.835 in.) 

   NOTE: Tighten the bolts within 10 minutes of sealant application.
   Fig 84: Installing Transaxle Housing And Bolts To Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   End play: 0.262 to 1.249 mm (0.0100 to 0.0494 in.) 

   Fig 85: Measuring Input Shaft End Play

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1. Fix the transaxle assembly.
Fig 86: Fixing Transaxle Assembly
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1. Coat a new oil seal with MP grease.
2. Install the oil seal to the transaxle case.

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

   Oil seal installation depth: 0 +- 0.5 mm (0 +- 0.197 in. ) 

Fig 87: Fixing Transaxle Assembly
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1. Install the parking lock rod to the manual valve lever.
Fig 88: Installing Oil Seal To Transaxle Case
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1. Install a new spacer and manual valve lever shaft to the transaxle case.
   NOTE: Do not damage the oil seal when installing the shaft to the transaxle case.
   Fig 89: Installing Parking Lock Rod To Manual Valve Lever

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch and hammer, drive in a new pin.
   Fig 90: Driving In Pin Using Pin Punch And Hammer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn the spacer and the lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.
4. Using a pin punch, stake the spacer through the small hole.
5. Check that the spacer does not turn.
Fig 91: Turning Spacer And Lever Shaft to Align
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1. Using needle-nose pliers, install the retainer spring.
   NOTE: Hang the spring on the shaft firmly.
Fig 92: Staking Spacer Through Small Hole
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1. 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.) 

   NOTE: Make sure that the parking rod is placed between the parking pawl and the guide of the parking bracket when the parking bracket is installed.
   Fig 93: Installing Parking Lock Pawl Bracket Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the manual detent spring and cover with the 2 bolts.
   NOTE: Make sure to install the manual detent spring and cover in this order.

   HINT:

   Tighten bolt A first, and then bolt 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 (1.063 in.) 

   Bolt B: 16 mm (0.630 in.) 

Fig 94: Installing Manual Detent Spring Sub-Assembly Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new O-ring with ATF, install it to the B-3 accumulator piston.
   NOTE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position.
   Fig 95: Installing O-Ring To B-3 Accumulator Piston

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the piston with ATF, install it to the transaxle case.
   NOTE: Install the springs to each accumulator piston, checking the identification color or each spring.
   Fig 96: Installing Piston to Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Accumulator spring: 

1. Coat 2 new O-rings with ATF, install them to the reverse accumulator piston.
   NOTE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position.
   Fig 97: Installing O-Rings To Reverse Accumulator Piston

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the piston with ATF, install it to the transaxle case.
   NOTE: Install the springs to each accumulator piston, checking the identification color or each spring.
   Fig 98: Installing Piston To Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Accumulator spring: 

1. Coat a new O-ring with ATF, install it to the C-3 accumulator piston.
   NOTE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position.
   Fig 99: Installing O-Ring To C-3 Accumulator Piston

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the piston with ATF, install it to the transaxle case.
   NOTE: Install the springs to each accumulator piston, checking the identification color or each spring.
   Fig 100: Installing Piston To Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Accumulator spring: 

   ACCUMULATOR SPRING
   
   

   Free length Outer diameter mm (in.)	Color
   72.20 (2.8425) / 19.0 (0.748)	Colorless

3. Install the spring to the C-3 accumulator piston.
   NOTE: Install the springs to each accumulator piston, checking the identification color or each spring.
Fig 101: Installing Spring To C-3 Accumulator Piston
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the check ball body with ATF.
2. Install the check ball body and spring.
   NOTE: Be sure to place the spring in the hole in the check ball body. Be careful about the direction of the parts.
   Fig 102: Identifying Check Ball And Spring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new brake drum gasket with ATF, install it to the transaxle case.
   NOTE: Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Be careful about the direction of parts.
Fig 103: Installing Check Ball Body And Spring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new transaxle case 2nd brake gasket with ATF, and install it to the transaxle case.
   NOTE: Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Be careful about the direction of parts.
Fig 104: Installing Transaxle Case 2nd Brake Gasket To Transaxle Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new governor apply gasket No. 1 with ATF, and install it to the transaxle case.
   NOTE: Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Be careful about the direction of parts.
   Fig 105: Installing Governor Apply Gasket No. 1 To Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new O-ring with ATF, and install it to the transmission wire.
   NOTE: Make sure that the O-ring is not twisted, protruded, or pinched when installing the wire transmission to the transaxle case. Apply sufficient ATF to the O-ring before installation.
Fig 106: Installing O-Ring To Transmission Wire
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the transmission wire retaining bolt.

   Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

Fig 107: Installing Transmission Wire Retaining Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat an O-ring of the ATF temperature sensor with ATF.
2. Install the ATF temperature sensor with the lock plate and bolt.

   Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf) 

3. Connect the 7 solenoid connectors.
   NOTE:

   • Connect the connectors A, B, C, D, E, F, G, in the order from shortest to longest.
   • Apply ATF to the bolt.

Fig 108: Installing ATF Temperature Sensor With Lock Plate And Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. While positioning 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: 41 mm (1.614 in.) 

   Bolt B: 57 mm (2.244 in.) 

   Bolt C: 25 mm (0.984 in.) 

   NOTE:

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

Fig 109: Identifying Transmission Valve Body Assembly Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new O-ring with ATF and install it to the oil strainer.
   NOTE: Make sure that the O-ring is not twisted or pinched. Apply sufficient ATF to the O-ring before installation.
   Fig 110: Installing O-Ring With ATF

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the oil strainer and 3 bolts to the valve body.

   Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) 

   NOTE: Apply ATF to the bolts.

Fig 111: View Of Oil Strainer And Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 2 magnets to the oil pan.
2. Apply seal packing or equivalent to new 18 bolts.

   Seal packing: 

   THREE BOND 2430 or equivalent 

   Fig 112: Installing Magnets To Oil Pan

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the oil pan and new oil pan gasket to the transaxle case with the 18 bolts.

   Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

   NOTE:

   • Tighten the bolts within 10 minutes of sealant application.
   • Completely remove any oil or grease from the contact surface of the transaxle case and the oil pan with the gasket before installing the oil pan to the case.

Fig 113: Identifying Oil Pan Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

Fig 114: Installing Transaxle Case Plugs To Transaxle Case

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat 2 new O-rings with ATF and install them to the 2 sensors.
2. Install the 2 sensors to the transaxle case with the 2 bolts.

   Torque: 11.0 N*m (115 kgf*cm, 8 ft.*lbf) 

Fig 115: Installing O-Rings To Sensors

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new O-ring with ATF, and install it to the elbow.
2. Install the elbow to the transaxle case.

   Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf) 

Fig 116: Installing O-Ring To Elbow

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new O-ring with ATF, and install it to the union.
2. Install the union to the transaxle case.

   Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

Fig 117: Installing Oil Cooler Tube Union (Inlet Oil Cooler Union)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the breather plug hose to the transaxle case firmly.

1. Install the park/neutral position switch onto the manual valve lever shaft, and temporarily install the 2 adjusting bolts.
2. Install a new nut stopper and nut.

   Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 

   Fig 118: Installing Nut Stopper And Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Temporarily install the control shaft lever.
   Fig 119: Installing Control Shaft Lever

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Turn the lever counterclockwise until it stops, and then turn it clockwise 2 notches.
5. Remove the control shaft lever.
   Fig 120: Removing Control Shaft Lever

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Align the groove with the neutral basic line.
   Fig 121: Aligning Groove With Neutral Basic Line

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Tighten the 2 bolts.

   Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

8. Using a screwdriver, stake the nut with the nut stopper.
   Fig 122: Staking Nut With Nut Stopper

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Install the control shaft lever, washer and nut.

   Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

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

   Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 

Fig 123: Identiyfing Speedometer Driven Hole (ATM) Cover Sub-Assembly Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002