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Automatic Transaxle Unit: Reassembly

  1. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING 
    1. Using SST and a press, install a new front drive pinion rear tapered roller bearing in to the differential case.

      SST 09710-30031 (09710-03161) 

      Fig 1: Installing Front Drive Pinion Rear Tapered Roller Bearing
      G04462952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the plate washer onto the transaxle case.
    3. Using SST and a press, press a new front drive pinion rear tapered roller bearing outer race in to the transaxle case.

      SST 09350-32014 (09351-32111, 09351-32130) 

      Fig 2: Placing Plate Washer Onto Transaxle Case
      G04462953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING 
    1. Install the speedometer drive gear to the differential case.
      Fig 3: Installing Speedometer Drive Gear To Differential Case
      G04462954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, install the new front drive pinion front tapered roller bearing in to the differential case.

      SST 09350-32014 (09351-32090, 09351-32130) 

      Fig 4: Installing Front Drive Pinion Front Tapered Roller Bearing In To Differential Case
      G04462955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, press a new front drive pinion front tapered roller bearing outer race in to the transaxle housing.

      SST 09350-32014 (09351-32111, 09351-32130) 

      Fig 5: Pressing Front Drive Pinion Front Tapered Roller Bearing Outer Race In To Transaxle Housing
      G04462956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL TRANSAXLE CASE OIL SEAL 
    1. Using SST and a hammer, drive in a new transaxle case oil seal.

      SST 09350-32014 (09351-32111, 09351-32130) 

    2. Coat the lip of transaxle case oil seal with MP grease.
      Fig 6: Installing Transaxle Case Oil Seal
      G04462957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL TRANSAXLE HOUSING OIL SEAL 
    1. Using SST and a hammer, drive in a new transaxle housing oil seal.

      SST 09350-32014 (09351-32130, 09351-32150) 

    2. Coat the lip of transaxle housing oil seal with MP grease.
      Fig 7: Installing Transaxle Housing Oil Seal
      G04462958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING 
    1. Using SST and a press, install the underdrive cylindrical roller bearing to the transaxle housing.

      SST 09350-32014 (09351-32140) 

      Fig 8: Installing Underdrive Cylindrical Roller Bearing To Transaxle Housing
      G04462959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the roller bearing retainer with a new seal washer and the bolt to the transaxle housing.

      Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) 

      Fig 9: Installing Roller Bearing Retainer With Seal Washer
      G04462960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE 
    1. Using a plastic hammer, install the differential gear lube apply tube to the transaxle housing.
      NOTE: Be careful not to bend or damage the tube.
  7. INSTALL TRANSMISSION LUBE APPLY TUBE 
    1. Using a plastic hammer, install the transmission lube apply tube to the transaxle housing.
      NOTE: Be careful not to bend or damage the tube.
      Fig 10: Installing Transmission Lube
      G04462961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL TRANSAXLE APPLY TUBE CLAMP NO. 2 
    1. Install the transaxle apply tube clamp No. 2 with the bolt to the transaxle housing.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

  9. INSTALL TRANSAXLE APPLY TUBE CLAMP NO. 1 
    1. Install the 2 transaxle apply tube clamp No. 1s with the 2 bolts to the transaxle housing.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Fig 11: Installing Transaxle Apply Tube Clamp
      G04462962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL COUNTER DRIVEN GEAR CYLINDRICAL ROLLER BEARING 
    1. Using SST and a press, install the counter driven gear cylindrical roller bearing to the transaxle case.

      SST 09350-32014 (09351-32090) 

  11. INSTALL TRANSMISSION CASE PLATE NO. 3 
    1. Install the transmission case plate No. 3 with the bolt to the transaxle case.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 12: Installing Transmission Case Plate
      G04462963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL B-4 ACCUMULATOR PISTON 
    1. Coat a new O-ring with ATF and install them to the B-4 accumulator piston.
    2. Install the B-4 accumulator piston and compression spring to the transaxle case.
      Fig 13: Installing B-4 Accumulator Piston
      G04462964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Clean the threads of the screws and case with white gasoline.
    4. Install a new transmission case plate No. 2 gasket and transmission case plate No. 2 in place to the transaxle case.
    5. Install and tighten the 2 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 14: Installing Transmission Case Plate
      G04462965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Apply seal packing or equivalent to the 7 screws.

      Seal packing: Part No. 08833 - 00070, THREE BOND 1324 or equivalent 

    7. Using a torx wrench, install the 7 screws.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

      Fig 15: Applying Seal Packing
      G04462966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL CAM GUIDE SLEEVE 
    1. Install the cam guide sleeve to the transaxle case.
      Fig 16: Installing CAM Guide Sleeve To Transaxle Case
      G04462967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL PARKING LOCK SLEEVE 
    1. Install the spring guide sleeve with the protruding portion facing up.
      Fig 17: Installing Parking Lock Sleeve
      G04462968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL PARKING LOCK PAWL 
    1. Place the pawl stopper plate on the protruding portion of the lock sleeve to the transaxle case.
      Fig 18: Installing Parking Lock Pawl
      G04462969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the spring guide sleeve and torsion spring with the 2 bolts.

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

      Fig 19: Installing Spring Guide Sleeve And Torsion Spring
      G04462970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the parking lock pawl to the transaxle case.
      Fig 20: Installing Parking Lock Pawl To Transaxle Case
      G04462971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the parking lock pawl shaft and pawl shaft clamp with a bolt.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Fig 21: Installing Parking Lock Pawl Shaft And Pawl Shaft Clamp
      G04462972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL UNDERDRIVE BRAKE PISTON 
    1. Coast 2 new O-rings with ATF and Install the 2 O-rings to the underdrive brake piston.
      Fig 22: Installing Underdrive Brake Piston
      G04462973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the underdrive brake piston into the case with the cup side up, being careful not to damage the O-rings.
      Fig 23: Placing Underdrive Brake Piston Into Case With Cup Side Up
      G04462974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Install the underdrive brake return spring subassembly to the transaxle case.
      Fig 24: Installing Underdrive Brake Return Spring Subassembly To Transaxle Case
      G04462975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL UNDERDRIVE CLUTCH DISC NO. 2 
    1. Install the 3 plates, 3 underdrive clutch disc No. 2s and flange in order.

      Install in order: D = Disc P = Plate F = Flange P - D - P - D - P - D - F 

      HINT:

      Install the flange with the flat side facing downward.

      Fig 25: Installing Underdrive Clutch Disc
      G04462976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place SST on the flange, and compress the flange with a press.

      SST 09350-32014 (09351-32070) 

    3. Using a screwdriver, install the underdrive clutch flange No. 2 hole snap ring to the transaxle case.

      HINT:

      Be sure the end gap of the snap ring is not aligned with one of the cutouts.

      Fig 26: Installing Underdrive Clutch Flange Hole Snap Ring To Transaxle Case
      G04462977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE (See  INSPECTION   ) 
  20. INSTALL OVERDRIVE CLUTCH DRUM OIL SEAL RING 
    1. Coat 2 new overdrive clutch drum oil seal rings with ATF and install the 2 overdrive clutch drum oil seal rings to the transaxle case.
      Fig 27: Installing Overdrive Clutch Drum Oil Seal Ring
      G04462978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY 
    1. Install the underdrive one-way clutch assembly to the transaxle case.
      Fig 28: Installing Underdrive Way Clutch Assembly To Transaxle Case
      G04462979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL UNDERDRIVE ONE-WAY CLUTCH RETAINER 
    1. In the place shown in the illustration (the space between the one-way clutch outer race and case), push the underdrive one-way clutch retainer in until you hear a "click".
  23. INSTALL UNDERDRIVE CLUTCH DRUM SUBASSEMBLY 
    1. Coat the underdrive clutch drum thrust washer with petroleum jelly and install it on to underdrive one-way clutch assembly.
    2. Align the flukes of discs in the underdrive brake.
    3. Install the underdrive clutch drum sub-assembly.
      Fig 29: Installing Underdrive Clutch Drum Sub-Assembly
      G04462980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the underdrive clutch assembly. The clutch assembly should turn freely counterclockwise and should lock clockwise.
      Fig 30: Identifying Underdrive Clutch Assembly
      G04462981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the assembled bearing and race, with the thrust needle roller bearing facing upward.

      Assembled bearing and race: mm (in.) 

      Fig 31: Installing Assembled Bearing And Race
      G04462982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      ASSEMBLED BEARING AND RACE SPECIFICATION

        Outer diameter Inner diameter
      Assembled bearing and race 43.9 mm (1.728 in.) 31.0 mm (1.220 in.)
  24. INSPECT HEIGHT OF CLUTCH ASSEMBLY (See  INSPECTION   ) 
  25. INSPECT PISTON STROKE OF UNDERDRIVE CLUTCH (See  INSPECTION   ) 
  26. INSTALL UNDERDRIVE PLANETARY SUN GEAR SUB-ASSEMBLY 
    1. Remove the underdrive planetary sun gear from the counter shaft assembly.
    2. Remove the underdrive input shaft needle roller bearing and underdrive input shaft thrust bearing race.
      Fig 32: Removing Underdrive Planetary Sun Gear From Counter Shaft Assembly
      G04462983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the underdrive planetary sun gear subassembly to the transaxle case.
    4. Coat the underdrive input shaft needle roller bearing and underdrive input shaft thrust bearing race with petroleum jelly and install it on the transaxle case.
  27. INSTALL COUNTER SHAFT ASSEMBLY 
    1. Align the flukes of the discs in the underdrive clutch.
    2. Install the needle roller bearing with the bearing facing upward.

      Bearing and race: mm (in.) 

      Fig 33: Installing Counter Shaft Assembly
      G04462984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      BEARING AND RACE SPECIFICATION

        Outer diameter Inner diameter
      Bearing 43.9 mm (1.728 in.) 31.0 mm (1.220 in.)
      Race 41.8 mm (1.646 in.) 30.0 mm (1.181 in.)
    3. Install the counter shaft assembly to the transaxle case.
  28. INSPECT HEIGHT OF COUNTER SHAFT (See  INSPECTION   ) 
  29. INSTALL COUNTER DRIVE GEAR BEARING 
    1. Install the new counter drive gear bearing to the counter drive gear.
    2. Install the new snap ring to the counter drive gear bearing.

      SST 09350-32014 (09351-32120) 

      Fig 34: Installing Snap Ring To Counter Drive Gear Bearing
      G04462985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL COUNTER DRIVE GEAR 
    1. Using SST and a press, install the counter drive gear.

      SST 09350-32014 (09351-32150, 09351-32130) 

      Fig 35: Installing Counter Drive Gear
      G04462986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL INTERMEDIATE SHAFT SUB-ASSEMBLY 
    1. Install the intermediate shaft sub-assembly to the transaxle case.
      Fig 36: Installing Intermediate Shaft Sub-Assembly To Transaxle Case
      G04462987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST to hold the counter drive gear, install the new counter drive gear nut.

      SST 09960-10010 (09962-01000, 09963-01000) 

      Torque: 180 N*m (1,835 kgf*cm, 133 ft.*lbf) 

  32. INSPECT DRIVE GEAR PRELOAD (See  INSPECTION   ) 
  33. TIGHTEN COUNTER DRIVE GEAR NUT 
    Fig 37: Inspecting Drive Gear Preload
    G04462988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL COUNTER DRIVEN GEAR 
    1. Install the thrust needle roller bearing to the transaxle case.

      Bearing: mm (in.) 

      Fig 38: Installing Thrust Needle Roller Bearing To Transaxle Case
      G04462989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      BEARING SPECIFICATION

        Outer diameter Inner diameter
      Bearing 58.0 mm (2.283 in.) 41.0 mm (1.614 in.)
    2. Using SST and a press, press in the counter driven gear.

      SST 09350-32014 (09351-32100, 09351-32140) 

      Fig 39: Pressing In Counter Driven Gear
      G04462990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST to hold the counter shaft assembly, tighten a new counter driven gear nut.

      SST 09350-32014 (09351-32032) 

      Torque: 180 N*m (1,835 kgf*cm, 133 ft.*lbf) 

  35. INSPECT END PLAY OF COUNTER SHAFT (See  INSPECTION   ) 
    Fig 40: Inspecting End Play Of Counter Shaft
    G04462991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. TIGHTEN COUNTER DRIVEN GEAR NUT 
    1. Using a pin punch and hammer, stake the counter driven gear nut.
      Fig 41: Tightening Counter Driven Gear Nut
      G04462992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL TRANSMISSION CASE COVER REAR 
    1. Remove any packing material and be careful not to get oil on the contacting surfaces of the transmission case cover rear or transaxle case.
    2. Apply FIPG sealant to the transmission case cover rear.

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

      Fig 42: Installing Transmission Case Cover Rear
      G04462993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install and tighten the 13 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      HINT:

      Each bolt length is indicated in the illustration.

      Bolt length: 

      Bolt A: 25 mm (0.98 in.) 

      Bolt B: 32 mm (1.26 in.) 

      Fig 43: Tightening Bolts With Torque Specification
      G04462994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSPECT INTERMEDIATE SHAFT SUB-ASSEMBLY (See  INSPECTION   ) 
  39. INSTALL 1ST AND REVERSE BRAKE PISTON 
    1. Coat the 2 new O-rings with ATF and install 2 new O-rings to the 1st & reverse brake piston.
      Fig 44: Installing 1st And Reverse Brake Piston
      G04462995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the 1st & reverse brake piston into the bore of the case, facing the spring seats upward.
      NOTE: Be careful not to damage the O-rings.
      Fig 45: Placing 1st Reverse Brake Piston Into Bore Of Case
      G04462996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Install the 1st & reverse brake return spring subassembly and snap ring in place.
      Fig 46: Installing 1st And Reverse Brake Return Spring Sub-Assembly
      G04462997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place SST on the 1st & reverse brake return spring sub-assembly, and compress the 1st & reverse brake return spring sub-assembly with a press.

      SST 09350-32014 (09351-32040) 

    3. Using snap ring pliers, install the snap ring.

      HINT:

      Visually check to make sure it is fully seated and centered by the 3 lugs on the spring retainer. Be sure the end gap of snap ring is aligned with the spring retainer claw.

      Fig 47: Installing Snap Ring
      G04462998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC 
    1. Install the 1st & reverse brake clutch discs and plates in order.

      HINT:

      6 plates and 6 discs.

      Install in order: D = Disc P = Plate 

      P - D - P - D - P - D - P - D - P - D - P - D 

      Fig 48: Installing 1st And Reverse Brake Clutch Disc
      G04462999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the outer flange with the flat side facing downward.
      Fig 49: Installing Outer Flange
      G04463000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, install the snap ring to the transaxle case.

      HINT:

      Be sure the snap ring end gap is not aligned with one of the cutouts.

      Fig 50: Installing Snap Ring To Transaxle Case
      G04463001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE (See  INSPECTION   ) 
  43. INSTALL REAR PLANETARY GEAR ASSEMBLY 
    1. Coat the thrust needle roller bearing and thrust bearing race with petroleum jelly and install them on to the intermediate shaft sub-assembly.

      Bearing and race: mm (in.) 

      Fig 51: Installing Rear Planetary Gear Assembly
      G04463002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      BEARING AND RACE SPECIFICATION

        Outer diameter Inner diameter
      Race 37.6 mm (1.480 in.) 24.1 mm (0.949 in.)
      Bearing 37.6 mm (1.480 in.) 22.1 mm (0.870 in.)
    2. Coat the planetary carrier thrust washer No. 2 with petroleum jelly and install it on to the rear planetary gear assembly.

      HINT:

      Make sure that the different lug shapes match the corresponding openings on the gear.

      Fig 52: Installing Rear Planetary Gear Assembly
      G04463003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the spline of the rear planetary gear assembly with the flukes of the discs and install the rear planetary gear assembly in to the 1st & reverse brake discs.
      Fig 53: Aligning Spline Of Rear Planetary Gear Assembly With Flukes Of Discs
      G04463004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Check the part "A" of the rear planetary gear assembly is below the upper surface of the flange.

      SST 09350-32014 (09351-32050) 

      Fig 54: Checking Rear Planetary Gear Assembly
      G04463005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Place the one-way clutch No. 2 assembly into the case, with the shiny side facing upward.
    6. Install the one-way clutch No. 2 assembly onto the inner race while turning the rear planetary gear assembly clockwise with SST.

      SST 09350-32014 (09351-32050) 

    7. Check that the rear planetary gear assembly turns freely clockwise and locks if turned counterclockwise.
      Fig 55: Placing Way Clutch Assembly Into Case
      G04463006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Coat the planetary carrier thrust washer No. 2 with petroleum jelly and install it on to the rear planetary gear assembly.
      Fig 56: Installing Thrust Washer
      G04463007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Be sure the end gap of the snap ring is not aligned with one of the cutouts.
      Fig 57: Measuring End Gap Of Snap Ring
      G04463008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL 2ND BRAKE CLUTCH DISC 
    1. Install the flange with the flat side facing upward.
      Fig 58: Installing Flange With Flat Side Facing Upward
      G04463009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 3 2nd brake clutch discs and 3 plates in order to the transaxle case.

      Install in order: D = Disc P = Plate 

      D - P - D - P - D - P 

      Fig 59: Installing 2nd Brake Clutch Discs And Plates
      G04463010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    1. Install each of the 2nd brake piston return spring sub-assembly over the protrusions in the transaxle case.
      Fig 60: Installing 2nd Brake Piston Return Spring Sub-Assembly
      G04463011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL 2ND COAST BRAKE BAND GUIDE PLATE 
    1. Install the 2nd coast brake band guide plate and brake band guide plate retainer so that its tip touches the transaxle case.
    2. Install the bolt.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Fig 61: Installing 2nd Coast Brake Band Guide Plate
      G04463012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL SECOND BRAKE PISTON ASSEMBLY 
    1. Align the groove of the drum with the bolt and place the 2nd brake piston assembly in to the transaxle case.
      Fig 62: Installing Second Brake Piston Assembly
      G04463013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place both ends of the snap ring in the groove, and then set the snap ring in to the transaxle case.
    3. While compressing the piston return springs over the drum with hammer handles, install the snap ring.

      HINT:

      Be sure the end gap of the snap ring is not aligned with one of the cutouts.

  48. INSPECT 2ND BRAKE PISTON (See  INSPECTION   ) 
    Fig 63: Inspecting 2nd Brake Piston
    G04463014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL ONE-WAY CLUTCH ASSEMBLY 
    1. Using a screwdriver, align the flukes of the discs in the 2nd brake.
      Fig 64: Aligning Flukes Of Discs In 2nd Brake
      G04463015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Align the spline of the one-way clutch assembly with the flukes of the discs and install the one-way clutch assembly to the 2nd brake discs.
  50. INSPECT 2ND BRAKE HUB INSTALLATION DISTANCE (See  INSPECTION   ) 
    Fig 65: Inspecting 2nd Brake Hub
    G04463016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL SUN GEAR INPUT DRUM ASSEMBLY 
    1. Coat the planetary carrier thrust washer No. 3 with petroleum jelly and install it on the planetary sun gear sub-assembly.
      Fig 66: Installing Sun Gear Input Drum Assembly
      G04463017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. By turning the planetary sun gear sub-assembly clockwise, install it in to the one-way clutch assembly.
      Fig 67: Installing Planetary Sun Gear Sub-Assembly
      G04463018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. INSTALL FRONT PLANETARY GEAR ASSEMBLY 
    1. Coat the thrust needle roller bearing with petroleum jelly and install it on to the front planetary gear assembly.

      Bearing: mm (in.) 

      Fig 68: Installing Front Planetary Gear Assembly
      G04463019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      BEARING SPECIFICATION

        Outer diameter Inner diameter
      Bearing 45.0 mm (1.772 in.) 28.1 mm (1.106 in.)
    2. Install the front planetary gear assembly.
      Fig 69: Installing Front Planetary Gear Assembly
      G04463020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL FRONT PLANETARY RING GEAR 
    1. Coat the thrust needle roller bearing and thrust bearing race with petroleum jelly and install them onto the front planetary gear assembly.

      Bearing and race: mm (in.) 

      Fig 70: Installing Front Planetary Ring Gear
      G04463021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      BEARING AND RACE SPECIFICATION (1 OF 2)

        Outer diameter Inner diameter
      Race 35.0 mm (1.378 in.) 19.0 mm (0.748 in.)
      Bearing 38.0 mm (1.496 in.) 22.0 mm (0.866 in.)
    2. Install the front planetary ring gear to the transaxle case.

      HINT:

      If the front planetary ring gear and the other parts are installed correctly into the case, the end of the bushing with the ring gear flange will be flush with or under the shoulder of the intermediate shaft.

      Fig 71: Installing Front Planetary Ring Gear To Transaxle Case
      G04463022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the thrust needle roller bearing and thrust bearing race with petroleum jelly and install them on to the tip of ring gear flange.

      Bearing and race: mm (in.) 

      Fig 72: Installing Tip Of Ring Gear Flange
      G04463023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      BEARING AND RACE SPECIFICATION (2 OF 2)

        Outer diameter Inner diameter
      Race 39.5 mm (1.555 in.) 26.0 mm (1.024 in.)
      Bearing 42.0 mm (1.654 in.) 25.8 mm (1.016 in.)
  54. INSTALL 2ND COAST BRAKE BAND ASSEMBLY 
    1. Place the 2nd coast brake band assembly in to the transaxle case.
    2. Install the pin to the transaxle case.
      Fig 73: Installing Pin To Transaxle Case
      G04463024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL INPUT SHAFT ASSEMBLY 
    1. Coat the thrust needle roller bearing with petroleum jelly and install it onto the forward clutch assembly.

      Assembled bearing and race: mm (in.) 

      INPUT SHAFT SPECIFICATION

        Outer diameter Inner diameter
      Assembled bearing and race 46.0 mm (1.811 in.) 30.7 mm (1.209 in.)
      Fig 74: Installing Input Shaft Assembly
      G04463025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the clutch drum thrust washer with petroleum jelly and install it onto the direct clutch drum with the oil groove facing upward.
      Fig 75: Installing Direct Clutch Drum With Oil Groove Facing Upward
      G04463026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, align the flukes of the discs in the direct clutch.
      Fig 76: Aligning Flukes Of Discs In Direct Clutch
      G04463027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Mesh the hub with the flukes of the direct clutch while turning the clutch drum or forward clutch.

      HINT:

      If the flukes of the discs are meshed correctly, the end of the bushing with the direct clutch will be flush with the surfaces of the forward clutch.

      Fig 77: Meshing Hub With Flukes Of Direct Clutch
      G04463028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Place the direct clutch assembly and forward clutch assembly in to the transaxle case.
    6. While rotating the forward clutch assembly to mesh the front planetary ring gear and discs, install them.
      Fig 78: Placing Direct Clutch Assembly
      G04463029Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Check the distance between A and B.

      Distance: Approx. 3 mm (0.118 in.) 

      Fig 79: Checking Distance Between A And B
      G04463030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL 2ND COAST BRAKE PISTON 
    1. Coat the 2 new O-rings with ATF and install the 2 O-rings to the 2nd coast brake cover.
      Fig 80: Installing 2nd Coast Brake Piston
      G04463031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the compression spring, 2nd coast brake piston and 2nd coast brake cover in to the bore.
      Fig 81: Installing Compression Spring, 2nd Coast Brake Piston
      G04463032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, install the snap ring.

      SST 09350-32014 (09351-32050) 

  57. INSPECT PISTON STROKE OF 2ND COAST BRAKE (See  INSPECTION   ) 
    Fig 82: Installing Snap Ring
    G04463033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. INSTALL GOVERNOR PRESSURE TUBE 
    1. Using a plastic hammer, install the governor pressure tube to the transaxle case.
      NOTE: Be careful not to bend or damage the tube.
      Fig 83: Installing Governor Pressure Tube To Transaxle Case
      G04463034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. INSTALL TRANSAXLE APPLY TUBE CLAMP NO. 3 
    1. Install the transaxle apply tube clamp No. 3 with the bolt.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Fig 84: Installing Transaxle Apply Tube Clamp
      G04463035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL OIL PUMP ASSEMBLY 
    1. Coat a new O-ring with ATF and install it to the oil pump assembly.
      Fig 85: Installing Oil Pump Assembly
      G04463036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the oil pump assembly through the input shaft, and align the bolt holes of the pump body with those of the transaxle case.
    3. Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings on the input shaft through the direct clutch drum.
      NOTE: Do not push on the oil pump strongly, or the oil seal ring will stick to the direct clutch drum.
      Fig 86: Placing Oil Pump Assembly
      G04463037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 6 bolts.

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

  61. INSPECT INPUT SHAFT ASSEMBLY (See  INSPECTION   ) 
  62. INSPECT INPUT SHAFT ENDPLAY (See  INSPECTION   ) 
    Fig 87: Inspecting Input Shaft Assembly
    G04463038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSTALL GOVERNOR APPLY GASKET NO. 2 
    1. Install the governor apply gasket No. 2 to the transaxle case.
  64. INSTALL TRANSMISSION CASE PLATE NO. 1 
    1. Install the transmission case plate No. 1 with the bolt.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 88: Installing Transmission Case Plate With Bolt
      G04463039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. INSTALL FRONT DIFFERENTIAL ASSEMBLY 
    1. Install the front differential assembly to the transaxle case.
      Fig 89: Installing Front Differential Assembly To Transaxle Case
      G04463040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. INSTALL TRANSAXLE HOUSING 
    1. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle housing or transaxle case.
    2. Apply FIPG to the transaxle housing.

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

      Fig 90: Installing Transaxle Housing
      G04463041Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply sealant to the bolt B threads.

      Sealant: Part No.08833 - 00090, adhesive 1131, or equivalent 

    4. Install the 17 bolts.

      Torque: 30 N*m (304 kgf*cm, 22 ft.*lbf) 

      HINT:

      Each bolt length is indicated in the illustration.

      Bolt length: 

      Bolt A: 30 mm (1.18 in.) 

      Fig 91: Installing Bolts With Torque Specification
      G04463042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt B: 35 mm (1.38 in.) 

  67. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. Using SST, rotate the differential in both directions to snug the bearing down.

      SST 09564-32011 

    2. Using SST and a torque wrench, measure the preload of the side bearing.

      SST 09564-32011 

      Torque: New bearing preload (at starting) 0.8 to 1.4 N*m (8 to 14 kgf*cm, 6.9 to 12.2 in.*lbf) 

      Used bearing preload (at starting) 0.4 to 0.7 N*m (4 to 7 kgf*cm, 3.5 to 6.1 in.*lbf) 

      Fig 92: Measuring Preload Of Side Bearing
      G04463043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the preload is not within the specified range, remove the differential from the transaxle case. Reselect the transaxle case side adjusting shim according to the following table.

      Adjusting shim thickness: mm (in.) 

      SHIM THICKNESS

      Thickness Thickness Thickness
      2.00 mm (0.0787 in.) 2.05 mm (0.0807 in.) 2.10 mm (0.0827 in.)
      2.15 mm (0.0846 in.) 2.20 mm (0.0866 in.) 2.25 mm (0.0886 in.)
      2.30 mm (0.0906 in.) 2.35 mm (0.0925 in.) 2.40 mm (0.0945 in.)
      2.45 mm (0.0965 in.) 2.50 mm (0.0984 in.) 2.55 mm (0.1004 in.)
      2.60 mm (0.1024 in.) 2.65 mm (0.1043 in.) 2.70 mm (0.1063 in.)
      2.75 mm (0.1083 in.) 2.80 mm (0.1102 in.) 2.85 mm (0.1122 in.)
      2.90 mm (0.1142 in.) 2.95 mm (0.1161 in.) 3.00 mm (0.1181 in.)

      HINT:

      The preload will change about 0.3 to 0.4 N*m (3 to 4 kgf*cm, 2.6 to 2.9 in.*lbf) according to a change in shim thickness of 0.05mm (0.0020 in.)

  68. INSTALL MANUAL VALVE LEVER SHAFT 
    1. Using a 14 mm (0.55 in.) socket wrench and hammer, drive in a new manual valve lever shaft oil seal.
    2. Apply MP grease to the seal lip.
      Fig 93: Installing Manual Valve Lever Shaft
      G04463044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the parking lock rod sub-assembly to the manual valve lever sub-assembly.
    4. Slide in the manual valve lever shaft and install the washer plate, a new spacer and manual valve lever sub-assembly.
      Fig 94: Installing Parking Lock Rod Sub-Assembly To Manual Valve Lever Sub-Assembly
      G04463045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the retainer spring.

      HINT:

      Make sure there is a washer between the retaining spring and case.

      Fig 95: Installing Retainer Spring
      G04463046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a pin punch and hammer, drive in the slotted spring pin.
    7. Position the spacer and stake it.
      Fig 96: Positioning Spacer And Stake
      G04463047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  69. INSTALL ACCUMULATOR PISTON AND SPRING 
    1. Coat 8 new O-rings with ATF and install them to the accumulator pistons 2 each.
    2. Install the accumulator pistons and compression springs to the transaxle case as shown in the illustration.
      ACCUMULATOR PISTON AND SPRING SPECIFICATION

      Spring Free length Color
      (1) C3 (Outer) 68.4 mm (2.815 in.) Yellow
      (2) C3 (Inner) 50 mm (1.968 in.) Yellow
      (3) B2 64.68 mm (2.685 in.) Light blue
      (4) C2 70.45 mm (2.773 in.) Purple
      (5) C1 (Outer) 60.39 mm (2.780 in.) Pink
      Fig 97: Installing Accumulator Piston And Spring
      G04463048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. INSTALL BRAKE DRUM GASKET 
    1. Install a new brake drum gasket until it makes contact with the 2nd brake drum.
      Fig 98: Installing Brake Drum Gasket
      G04463049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. INSTALL GOVERNOR APPLY GASKET NO. 1 
    1. Install the new governor apply gasket No. 1 to the transaxle case.
      Fig 99: Installing Governor Apply Gasket
      G04463050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. INSTALL CHECK BALL BODY 
    1. Install the check ball body and compression spring to the transaxle case.
      Fig 100: Installing Check Ball Body And Compression Spring To Transaxle Case
      G04463051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. INSTALL TRANSMISSION WIRE 
    1. Coat a new O-ring with ATF and install the transmission wire to the transaxle case.
      Fig 101: Installing Transmission Wire
      G04463052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bolt.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Fig 102: Installing Bolt With Torque Specification
      G04463053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. INSTALL TRANSMISSION VALVE BODY ASSEMBLY 
    1. Connect the manual valve connecting rod to the manual valve lever.
      Fig 103: Installing Transmission Valve Body Assembly
      G04463054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transmission valve body assembly with the 17 bolts.

      HINT:

      Each bolt length is indicated in the illustration.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Bolt length: 

      Bolt A: 20 mm (0.79 in.) 

      Bolt B: 28 mm (1.10 in.) 

      Bolt C: 50 mm (1.97 in.) 

      Fig 104: Installing Transmission Valve Body Assembly
      G04463055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the solenoid connectors.
      Fig 105: Connecting Solenoid Connectors
      G04463056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. INSTALL MANUAL DETENT SPRING SUBASSEMBLY 
    1. Install the manual detent spring sub-assembly and manual detent spring cover with the bolt.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 106: Installing Manual Detent Spring Subassembly
      G04463057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. INSTALL VALVE BODY OIL STRAINER ASSEMBLY 
    1. Install the valve body oil strainer assembly and a new oil strainer gasket with the 3 bolts.

      HINT:

      Each bolt length is indicated in the illustration.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Bolt length: 

      Bolt A: 12 mm (0.47 in.) 

      Bolt B: 20 mm (0.79 in.) 

      Fig 107: Installing Valve Body Oil Strainer Assembly
      G04463058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. INSTALL TRANSMISSION OIL CLEANER MAGNET 
    1. Install the 2 transmission oil cleaner magnets to the automatic oil pan sub-assembly.
      Fig 108: Installing Transmission Oil Cleaner Magnet
      G04463059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY 
    1. Install a new automatic transaxle oil pan gasket to the automatic transaxle oil pan sub-assembly and install them to the transaxle.
    2. Tighten the 18 bolts.

      Torque: 5.3 N*m (54 kgf*cm, 47 in.*lbf) 

      Fig 109: Installing Automatic Transaxle Oil Pan Subassembly
      G04463060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. INSTALL OIL COOLER TUBE UNION 
    1. Coat 2 new O-rings with ATF and install 2 new O-rings to the 2 oil cooler tube unions.
    2. Install the 2 oil cooler tube unions to the transaxle case.

      Torque: 30 N*m (304 kgf*cm, 22 ft.*lbf) 

      Fig 110: Installing Oil Cooler Tube Union
      G04463061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY 
    1. Install the park / neutral position switch assembly to the manual valve lever shaft.
    2. Place a new lock washer and tighten the nut.

      Torque: 12 N*m (122 kgf*cm, 8 ft.*lbf) 

    3. Temporarily install the 2 bolts.
      Fig 111: Installing Park / Neutral Position Switch Assembly
      G04463062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporarily install the transmission control shift lever.
    5. Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches.
    6. Remove the transmission control shift lever.
      Fig 112: Removing Transmission Control Shift Lever
      G04463063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Align the groove with neutral basic line.
    8. Tighten the 2 bolts.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Fig 113: Aligning Groove With Neutral Basic Line
      G04463064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Using a screwdriver, stake the nut with the lock washer.
  81. INSTALL TRANSMISSION CONTROL SHAFT LEVER 
    1. Install the transmission control shaft lever with the nut and washer.

      Torque: 12 N*m (122 kgf*cm, 8 ft.*lbf) 

  82. INSTALL TRANSAXLE CASE NO. 1 PLUG 
    1. Install the transaxle case No. 1 plug and a new O-ring to the transaxle case.
  83. INSTALL BREATHER PLUG NO. 1 (ATM) 
    1. Install the breather plug No. 1 and a new O-ring to the transaxle case.
      Fig 114: Installing Breather Plug
      G04463065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. INSTALL BREATHER PLUG HOSE 
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