Automatic Transaxle Unit: Reassembly

BEARING POSITION

Check each bearing position and installation direction.

Fig 1: Bearing Position And Installation Direction

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard Bearing Position

STANDARD BEARING POSITION CHART

Mark	Front Race Diameter (mm (in.)) Inside/Outside	Thrust Bearing Diameter (mm (in.)) Inside/Outside	Rear Race Diameter (mm (in.)) Inside/Outside
A	-	57.2 (2.25)/84.96 (3.34)	56.4 (2.220)/83.0 (3.268)
B	-	37.73 (1.49)/58.0 (2.28)	29.9 (1.18)/55.5 (2.19)
C	-	33.85 (1.33J/52.2 (2.06)	-
D	-	23.5 (0.925)/44.0 (1.73)	-
E	-	36.3 (1.43)/52.2 (2.06)	34.5 (1.36)/48.5 (1.91)
F	-	34.6 (1.362)/52.2 (2.06)	-
G	40.3 (1.59)/58.0 (2.28)	38.6 (1.52)/60.0 (2.36)	38.6 (1.52)/58.0 (2.28)
H		53.6 (2.11)/69.6 (2.74)	-
I	-	33.8 (1.33)/48.2 (1.90)	30.3 (1.19)/46.0 (1.81)
J	-	53.6 (2.11)/70.18 (2.76) or 69.6 (2.74)	-

INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
1. Install the apply tube and clamp to the transaxle housing with the bolt.
  Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
  
  NOTE: Make sure to insert the pipe to the stopper.
  
  Fig 2: Identifying Transaxle Bolt And Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING
1. Install a new oil seal ring to the transaxle housing.
Fig 3: Identifying Oil Seal Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING
1. Using SST and a press, press in the underdrive cylindrical roller bearing.
  SST 09950-60020 (09951-00810), 09950-70010 (09951-07100)
  
  NOTE: Do not apply excessive pressure.
  
  Fig 4: Installing Underdrive Cylindrical Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING
1. Install 2 new oil seal rings to the transaxle.
Fig 5: Identifying Underdrive Clutch Drum Oil Seal Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE BRAKE PISTON
1. Wrap vinyl tape around SST 4.0 mm (0.157 in.) above from the bottom end until the thickness of the wrapped tape is about 5.0 mm (0.197 in.)
  SST 09950-60010 (09951-00320)
  
  NOTE: Clean SST to remove oil deposits before wrapping with vinyl tape.
  
  Fig 6: Identifying Vinyl Tape Around SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in the needle-roller bearing to the transaxle until the wrapped vinyl tape contacts the transaxle case.
  SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)
  
  Fig 7: Pressing Needle-Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat 2 new O-rings with ATF, and install them to the underdrive brake piston.
  
  Fig 8: Locating O-rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the underdrive brake piston to the transaxle.
  
  Fig 9: Identifying Underdrive Brake Piston On Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, a snap ring expander and press, press in the piston return spring and snap ring to the transaxle.
  SST 09387-00020
  
  NOTE: Do not apply excessive pressure.
INSTALL NO. 2 BREATHER PLUG

Fig 10: Installing Snap Ring And Underdrive Brake Return Spring Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COUNTER DRIVE GEAR HOLE SNAP RING
1. Using a screwdriver, press in the snap ring to the transaxle.
Fig 11: Prying Snap Ring Of Transaxle
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COUNTER DRIVE GEAR
1. Using SST and a press, press in the 2 bearing outer races to the transaxle.
  SST 09950-60020 (09951-00890), 09950-70010 (09951-07150)
  
  Fig 12: Installing Counter Drive Gear And Front Planetary Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in the tapered roller bearing to the counter drive gear until the bearing race contacts the snap ring.
  SST 09649-17010
  
  NOTE: Do not apply excessive pressure.
  
  Fig 13: Pressing 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.
  SST 09950-70010 (09951-07150), 09950-60020 (09951-00750)
  
  NOTE: Do not apply excessive pressure.
  
  Fig 14: Installing Counter Drive Gear And Bearing To Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST AND REVERSE BRAKE PISTON
1. Coat 2 new O-rings with ATF.
2. Install the 2 O-rings to the 1st and reverse brake piston.
  
  Fig 15: Locating O-rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the 1st and reverse brake piston with ATF, and install it to the transaxle.
  
  Fig 16: Identifying 1st And Reverse Brake Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
1. Using SST, a press and snap ring expander, press the 1st and reverse brake return spring sub-assembly and snap ring to the transaxle.
  
  Fig 17: Removing/Installing Snap Ring And 1st And Reverse Brake Return Spring Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09387-00070
  NOTE:
  - Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0-0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
  - Do not expand the snap ring excessively.
INSTALL FRONT PLANETARY RING GEAR
1. Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.
Fig 18: Identifying Front Planetary Ring Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT PLANETARY GEAR ASSEMBLY
1. Install the front planetary gear assembly to the brake hub.
  
  Fig 19: Installing Front Planetary Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press-fit the front planetary gear.
  SST 09950-60010 (09951-00500), 09950-70010 (09951-07100)
  
  NOTE: Do not apply excessive pressure.
  
  Fig 20: Pressing Front Planetary Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install anew washer as shown in the illustration.
  
  Fig 21: Identifying Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, install the nut.
  SST 09387-00030, 09387-00080
  
  Torque: 280 N*m (2855 kgf*cm, 206 ft.*lbf)
  
  Fig 22: Installing Nut Using SST
  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. If the measured value is not within the specified value, gradually tighten the nut until it reaches the specified value.
  
  Fig 23: Measuring Turning Torque Of Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09387-00080
  
  Torque: Turning torque at 60 rpm
  
  0.5 to 1.0 N*m (5 to 10 kgf*cm, 4 to 9 in.*lbf) for a new bearing
  
  0.3 to 0.5 N*m (3 to 5 kgf*cm, 3 to 4 in.*lbf) for a used bearing
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
6. Using a chisel and hammer, stake the washer.
Fig 24: Staking Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL INPUT SUN GEAR

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

Standard Bearing and Race Diameter

BEARING DIAMETER CHART

Item	Inside (mm (in.))	Outside (mm (in.))
Bearing	34.6 (1.362)	52.2 (2.055)
Race	40.3 (1.587)	58.0 (2.283)
Bearing	38.6 (1.52)	60.0 (2.362)

Fig 25: Identifying Thrust Bearings, Bearing Race And Input Sun Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR PLANETARY GEAR ASSEMBLY

Coat the bearing race with ATF, and install it to the rear planetary gear assembly.

Standard Race Diameter

BEARING DIAMETER CHART

Item	Inside (mm (in.))	Outside (mm (in.))
Race	38.6 (1.520)	58.0 (2.28)

Fig 26: Identifying Bearing Race On Rear Planetary Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the No. 1 washer.

Fig 27: Identifying No. 1 Washer On Rear Planetary Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the rear planetary gear to the brake hub.

Fig 28: Identifying Rear Planetary Gear Of Transaxle
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a screwdriver, install the snap ring.

Fig 29: Installing Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC

Install the 5 plates and 5 discs.
Install in order:

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

HINT:

P = Plate

D = Disc

Fig 30: Identifying Clutch Plates And Discs
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a vernier caliper, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle (Dimension A).

Select an appropriate flange so that the pack clearance will meet the specified value. 0.75 to 1.21 mm (0.0295 to 0.0476 in.)

Fig 31: Measuring Distance Between Disc Surface And Contact Surface Of 2nd Brake Cylinder

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Pack clearance = Dimension A - Flange thickness

Flange Thickness

FLANGE THICKNESS CHART

Mark	Thickness (mm (in.))	Mark	Thickness (mm (in.))
1	1.8 (0.0709)	5	2.2 (0.0866)
2	1.9 (0.0748)	6	2.3 (0.0906)
3	2.0 (0.0787)	7	2.4 (0.0945)
4	2.1 (0.0827)	8	2.5 (0.0984)

Install the flange.

Fig 32: Identifying Flange

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL 2ND BRAKE PISTON O-RING
1. Coat 2 new O-rings with ATF, and install them into the 2nd brake piston.
Fig 33: Identifying 2nd Brake Piston O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND BRAKE PISTON
1. Press the 2nd brake piston into the 2nd brake cylinder by hand.
Fig 34: Installing 2nd Brake Piston
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
1. Install the piston return spring.
  
  Fig 35: Identifying 2nd Brake Piston Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place SST on the piston return spring, and compress the piston return spring with a press.
  SST 09387-00060
3. Using a screwdriver, install the snap ring.
  NOTE: Be sure that the end gap of the snap ring is not aligned with the piston return spring claw.
  
  Fig 36: Prying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND BRAKE PISTON ASSEMBLY
1. Install the 2nd brake piston to the transaxle.
2. Install the snap ring and measure the inside diameter.
  Standard inside diameter:
  
  More than 167 mm (6.57 in.)
  NOTE:
  - Check the direction of the tapered snap ring when installing it.
  - If the diameter does not satisfy the specified value, replace the snap ring with a new one.
  Fig 37: Identifying 2nd Brake Piston Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ONE-WAY CLUTCH OUTER SLEEVE
1. Install the one-way clutch outer sleeve to the 2nd brake cylinder.
  NOTE: Check the direction of the outer sleeve.
  
  Fig 38: Identifying One-Way Clutch Outer Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL ONE-WAY CLUTCH ASSEMBLY

Install the inner race to the one-way clutch.
NOTE: Check the direction of the inner race.

Fig 39: Identifying Inner Race And One-Way Clutch
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check that the one-way clutch turns freely counterclockwise and locks when turned clockwise.

Fig 40: Checking One-Way Clutch Rotation
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard Thrust Bearing Diameter

STANDARD THRUST BEARING DIAMETER CHART

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Bearing	53.6 (2.110)	69.6 (2.740)

NOTE: Install the thrust bearing properly so that un-colored race will be visible.

Fig 41: Identifying One-Way Clutch And Thrust Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

Coat the No. 2 washer with petroleum jelly, and install it onto the rear planetary sun gear.

Fig 42: Identifying No.2 Washer On Rear Planetary Sun Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard Thrust Bearing Diameter

STANDARD THRUST BEARING DIAMETER CHART

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Bearing	33.8 (1.331)	48.2 (1.898)

Fig 43: Identifying Thrust Bearing And Rear Planetary Sun Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 44: Identifying Rear Planetary Sun Gear Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL 2ND BRAKE CLUTCH DISC

Install the 3 discs and 3 plates to the transaxle.
Install in order:

P - D - P - D - P - D

HINT:

P = Plate

D = Disc
Temporarily install the snap ring.

Fig 45: Identifying 2nd Brake Clutch Disc And Plates
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a vernier caliper, measure the distance between the disc surface and snap ring surface.

Select an appropriate flange so that the pack clearance will meet the specified value.

Standard pack clearance:

0.50 to 0.91 mm (0.0197 to 0.0358 in.)

Fig 46: Measuring Distance Between Disc And Snap Ring Surface

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Pack clearance = Clearance - Flange thickness - Snap ring thickness 1.6 mm (0.063 in.)

Flange Thickness

FLANGE THICKNESS CHART

Mark	Thickness (mm (in.))	Mark	Thickness (mm (in.))
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	-

Temporarily remove the snap ring, attach the selected flange and reinstall the snap ring.
NOTE: Position the snap ring so that its gap is visible through the groove of the transaxle case.

Fig 47: Identifying Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Coat the direct clutch piston with ATF, and install it to the direct clutch drum.
  NOTE: Be careful not to damage the lip seal of the direct clutch piston.
  
  Fig 48: Installing Direct Clutch Return Spring Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the direct clutch return spring sub-assembly to the direct clutch drum.
  
  Fig 49: Installing Direct Clutch Return Spring Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the clutch balancer to the direct clutch drum.
  NOTE: Be careful not to damage the lip seal of the direct clutch balancer.
  
  Fig 50: Removing/Installing Clutch Balancer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place SST on the clutch balancer and compress the piston return spring with a press.
  SST 09387-00020
5. Using a snap ring expander, install the snap ring to the direct clutch drum.
  
  Fig 51: Installing Snap Ring To Direct Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be sure the end gap of the snap ring is not aligned with the clutch balancer claw.
  - Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
  - Do not expand the snap ring excessively.
INSTALL DIRECT MULTIPLE DISC CLUTCH DISC
1. Install the 3 plates, 3 discs and flange to the direct clutch drum.
  Install in order:
  
  P - D - P - D - P - D - F
  
  HINT:
  
  P = Plate
  
  D = Disc
  
  F = Flange
  
  Fig 52: Identifying Plates, Discs And Flange On Direct Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the snap ring.
3. Check that the end gap of the snap ring is not aligned with one of the cutouts.
INSPECT PACK CLEARANCE OF DIRECT CLUTCH (See INSPECTION )
INSPECT DIRECT MULTIPLE DISC CLUTCH DISC (See INSPECTION )

Fig 53: Removing/Installing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL DIRECT CLUTCH

Install the bearing race to the direct clutch.

Standard Bearing Race Diameter

STANDARD BEARING DIAMETER CHART

Item	Inside (mm (in.))	Outside (mm (in.))
Bearing Race	30.3 (1.193)	46.0 (1.811)

Fig 54: Identifying Bearing Race And Direct Clutch

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the direct clutch and thrust bearing to the rear planetary sun gear.
NOTE: The discs in the direct clutch should be completely mated with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed.

Fig 55: Identifying Thrust Bearing And Direct Clutch Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Clean the connector part of the transaxle case and rear cover.
As shown in the illustration, place a straightedge on the direct clutch drum and measure the distance between the transaxle case and the straightedge using a vernier caliper (Dimension B).

Fig 56: Measuring Distance Between Transaxle Case And Straightedge
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Measure the 2 places of the rear cover as shown in the illustration. Calculate dimension C using the following formula:
HINT:

Dimension C = Dimension (1) - Dimension (2)

Calculate the end play value using the following formula:

NOTE: Make sure that the colored race side is facing the direct clutch assembly.

Fig 57: Identifying Rear Cover Dimensions

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

End play = Dimension C - Dimension B

End play:

0.20 to 0.93 mm (0.00787 to 0.0366 in.)

Select a thrust bearing which satisfies the end play value and install it.

Standard Bearing Thickness and Diameter

STANDARD BEARING THICKNESS CHART

Thickness	Inside (mm (in.))	Outside (mm (in.))
3.58 mm (0.1409 in.)	53.6 (2.110)	69.6 (2.740)
3.88 mm (0.1528 in.)	53.6 (2.110)	70.18 (2.763)

INSTALL NO. 1 GOVERNOR APPLY GASKET
1. Install 2 new governor apply gaskets.
Fig 58: Locating No. 1 Governor Gasket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT CLUTCH APPLY TUBE
1. Install the clamp to the front clutch 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.
  
  Fig 59: Identifying Front Clutch Apply Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE APPLY TUBE
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.
  
  Fig 60: Identifying Brake Apply Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 apply tubes and to the transaxle with the bolt.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  NOTE: Each pipe should be securely inserted until it reaches the stopper.
  
  Fig 61: Identifying Clutch Apply Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 TRANSAXLE CASE PLUG
1. Install 2 new O-rings to the 2 plugs.
2. Install the 2 plugs to the transaxle rear cover.
  Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
  
  Fig 62: Identifying No. 1 Transaxle Case Plugs And O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY
1. Using SST and a press, press in the needle roller bearing.
  SST 09950-60010 (09951-00230, 09952-06010)
  
  Standard depth:
  
  12.05 to 12.75 mm (0.474 to 0.501 in.)
  NOTE:
  - Face the inscribed side of the bearing race up.
  - Keep pressing until the specified value is obtained.
2. Apply adhesive to the 2 screws.
  Adhesive:
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
  
  Fig 63: Position Of Placing Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a T30 "TORX" socket wrench, install the transaxle rear cover plate with the 2 screws.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
  
  Fig 64: Identifying Transaxle Rear Cover Plate Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Coat 2 new oil seal rings with ATF, and install them to the transaxle rear cover.
  
  Fig 65: Identifying Oil Seal Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove any packing material and be careful not to get oil on the contact surfaces of the transaxle rear cover or the transaxle.
6. Apply FIPG to the cover.
  FIPG:
  
  Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
7. Coat the needle roller bearing with ATF.
  
  Fig 66: Identifying FIPG Location On Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Apply adhesive to the threads of the bolts labeled A.
  Adhesive:
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
9. Install the 11 bolts.
  Torque: Bolt A .
  
  19 N*m (194 kgf*cm, 14 ft.*lbf)
  
  Other bolts
  
  25 N*m (255 kgf*cm, 18 ft.*lbf)
  
  Fig 67: Identifying Transaxle Rear Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 2 UNDERDRIVE CLUTCH DISC

Install the 3 discs and 3 plates to the transaxle.
Install in order:

P - D - P - D - P - D

HINT:

P = Plate

D = Disc
Using a screwdriver, install the snap ring.

Fig 68: Identifying No. 2 Underdrive Clutch Discs And Plates
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 69: Measuring Underdrive Brake Pack Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard pack clearance:

1.59 to 2.20 mm (0.0626 to 0.0866 in.)

HINT:

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

Standard Flange Thickness

STANDARD FLANGE THICKNESS CHART

Mark	Thickness (mm (in.))	Mark	Thickness (mm (in.))
1	3.0 (0.118)	3	3.4 (0.134)
2	3.2 (0.126)	-	-

Temporarily remove the snap ring and attach the flange. Reinstall the snap ring.

INSPECT UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY (See INSPECTION )
INSTALL UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY
1. Install the outer race retainer to the one-way clutch.
  
  Fig 70: Identifying Outer Race Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the one-way clutch to the transaxle.
  NOTE: Make sure that the mark on the one-way clutch outer race is visible.
  
  Fig 71: Identifying One-Way Clutch On Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, install the snap ring to the transaxle.
Fig 72: Removing/Installing Snap Ring On Transaxle
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE CLUTCH PISTON SET
1. Coat the underdrive clutch piston with ATF, and install it to the underdrive clutch piston drum.
  NOTE: Be careful not to damage the O-ring.
  
  Fig 73: Installing Underdrive Clutch Piston Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the underdrive piston return spring sub-assembly to the underdrive clutch drum.
  
  Fig 74: Installing Underdrive Piston Return Spring Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the clutch balancer to the underdrive clutch drum.
  NOTE: Be careful not to damage the lip seal of the clutch balancer.
  
  Fig 75: Removing/Installing Clutch Balancer And Underdrive Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place SST on the clutch balancer and compress the piston return spring with a press.
  SST 09350-32014 (09351-32070)
5. Using a snap ring expander, install the snap ring to the underdrive clutch drum.
  
  Fig 76: Installing Snap Ring To Underdrive Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be sure the end gap of the snap ring is not aligned with the clutch balancer claw.
  - Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
  - Do not expand the snap ring excessively.
6. Set the end gap of the snap ring in the underdrive clutch drum as shown in the illustration.
  NOTE: Do not align the end gap of the snap ring with any of the stoppers.
  
  Fig 77: Identifying Stopper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE CLUTCH DRUM O-RING
1. Coat a new O-ring with ATF, and install it to the underdrive clutch drum.
Fig 78: Identifying Underdrive Clutch Drum O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 UNDERDRIVE CLUTCH DISC
1. Install the 3 plates, 3 discs and flange to the underdrive clutch drum.
  Install in order:
  
  P - D - P - D - P - D - F
  
  HINT:
  
  P = Plate
  
  D = Disc
  
  F = Flange
  
  Fig 79: Identifying No. 1 Underdrive Clutch Discs, Plates And Flanges
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the underdrive clutch flange hole snap ring.
3. Check that the end gap of the snap ring is not aligned with one of the cutouts.
INSPECT PACK CLEARANCE OF UNDERDRIVE CLUTCH (See INSPECTION )

Fig 80: Installing Underdrive Clutch Flange Hole Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL UNDERDRIVE CLUTCH ASSEMBLY

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

Standard Bearing and Race Diameter

STANDARD BEARING AND DIAMETER CHART

Item	Inside (mm (in.))	Outside (mm (in.))
Bearing	37.73 (1.4854)	58.0 (2.283)
Race	29.9(1.177)	55.5 (2.185)

Install the underdrive clutch to the transaxle.

Fig 81: Identifying Underdrive Clutch Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL UNDERDRIVE PLANETARY RING GEAR
1. Install a new snap ring to the outer race of the angular ball bearing.
  HINT:
  
  If replacing the bearing, also replace the counter driven gear with a new one.
  
  Fig 82: Installing Snap Ring To Outer Race Of Angular Ball Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a piston ring compressor, squeeze the snap ring.
  
  Fig 83: Squeezing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, press in the outer race of the angular ball bearing.
  SST 09950-60020 (09951-00890), 09950-70010 (09951-07100)
  
  NOTE: Do not damage the snap ring during installation of the outer race.
  
  Fig 84: Pressing In Outer Race Of Angular Ball Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the underdrive planetary ring gear to the counter driven gear.
  
  Fig 85: Identifying Underdrive Planetary Ring Gear And Counter Driven Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using snap ring pliers, install the snap ring.
Fig 86: Installing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY
1. Using SST and a press, press the angular ball bearing inner race (rear side) into the underdrive planetary gear.
  SST 09726-40010, 09950-60010 (09951-00260), 09950-70010 (09951-07100)
  
  Fig 87: Pressing Angular Ball Bearing Inner Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the counter driven gear with planetary ring gear to the underdrive planetary gear.
  
  Fig 88: Installing Counter Driven Gear With Planetary Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, press in the angular ball bearing inner race (front side).
  SST 09726-40010, 09950-60010 (09951-00260), 09950-70010 (09951-07100)
  
  NOTE: Rotate the counter driven gear while pressing.
  
  Fig 89: Pressing In Angular Ball Bearing Inner Race (Front Side)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST and a press, press in the parking lock gear.
  SST 09316-20011, 09950-60010 (09951-00260), 09950-70010 (09951-07100)
  
  NOTE: Rotate the counter driven gear while pressing.
  
  Fig 90: Pressing Parking Lock Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST and a press, press in the differential drive pinion.
  SST 09726-40010, 09950-60010 (09951-00260), 09950-70010 (09951-07100)
  
  NOTE: Rotate the counter driven gear while pressing.
  
  Fig 91: Pressing Differential Drive Pinion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDRICAL ROLLER BEARING INNER RACE
1. Using SST and a press, press in the cylindrical roller bearing inner race.
  SST 09515-21010, 09950-60010 (09951-00260), 09950-70010 (09951-07100)
  
  NOTE: Rotate the counter driven gear while pressing.
  
  Fig 92: Pressing Cylindrical Roller Bearing Inner Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE INPUT SHAFT NUT
1. Clamp the underdrive planetary gear in a soft jaw vise.
  NOTE: Be careful not to damage the differential drive pinion.
  
  Fig 93: Clamping Underdrive Planetary Gear In Soft Jaw Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a socket wrench, install a new lock nut.
  Torque: 280 N*m (2855 kgf*cm, 207 ft.*lbf)
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 750 mm (29.53 in.)
INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD (See INSPECTION )
INSTALL UNDERDRIVE INPUT SHAFT NUT
1. Using a pin punch and a hammer, stake the lock nut.
  NOTE: Make sure that there are no cracks on the nut.
  
  Fig 94: Staking Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE PLANETARY GEAR
1. Install the pawl pin and spring to the parking lock pawl.
  
  Fig 95: Identifying Pawl Pin And Spring
  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 96: Installing Parking Lock Pawl
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the underdrive planetary gear to the transaxle.
  NOTE: Firmly engage all the discs of the underdrive clutch with the hub splines of the underdrive planetary gear assembly.
  
  Fig 97: Removing/Installing Underdrive Planetary Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the parking lock pawl shaft.
  
  Fig 98: Locating Parking Lock Pawl Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the pawl shaft clamp with the bolt.
  Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
  
  Fig 99: Identifying Bolt And Parking Pawl Shaft Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a straightedge and a vernier caliper as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and contact surface of the transaxle and housing (Dimension D).
  NOTE: Make a note of dimension D as it is necessary for the following process.
  
  Fig 100: Measuring Gap Between Top Of Differential Drive Pinion In Underdrive Planetary Gear And Contact Surface Of Transaxle And Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. As shown in the illustration, measure the 2 places of the transaxle housing. Calculate dimension E using the following formula:
  NOTE: Make a note of dimension E as it is necessary for the following process.
  
  HINT:
  
  Dimension E = Dimension (1) - Dimension (2)
  
  Fig 101: Identifying Transaxle Housing Dimensions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL MULTIPLE DISC CLUTCH HUB

Install the bearing race to the transaxle while checking its direction.

Standard Bearing Race Diameter

STANDARD BEARING AND DIAMETER CHART

Item	Inside (mm (in.))	Outside (mm (in.))
Bearing Race	34.5 (1.358)	48.5 (1.909)

Fig 102: Position Of Installing Bearing Race

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Coat the thrust bearing with petroleum jelly, and install them onto the multiple disc clutch hub.

Standard Thrust Bearing Diameter

STANDARD BEARING AND DIAMETER CHART

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Bearing	36.3 (1.429)	52.2 (2.055)

Fig 103: Identifying Thrust Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the bearing to the multiple disc clutch hub.

Standard Bearing Diameter

STANDARD BEARING AND DIAMETER CHART

Item	Inside (mm (in.))	Outside (mm (in.))
Bearing	23.5 (0.925)	44.0 (1.732)

Install the multiple disc clutch hub to the transaxle.

Fig 104: Identifying Multiple Disc Clutch Hub

INSTALL INPUT SHAFT OIL SEAL RING
1. Compress the oil seal ring from both sides to reduce dimension A.
  Standard dimension A:
  
  5 mm (0.197 in.)
2. Coat the oil seal ring with ATF and install it to the input shaft.
Fig 105: Installing Input Shaft Oil Seal Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY
1. Coat 2 new O-rings with ATF, and install them to the forward clutch piston.
  
  Fig 106: Installing Forward Clutch Piston Sub-Assembly O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the forward clutch piston to the forward clutch drum.
Fig 107: Installing Forward Clutch Piston
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Place the return spring onto the piston.
  
  Fig 108: Identifying Forward Clutch Return Spring Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place SST on the return spring, and compress the return spring with a press.
  SST 09350-32014
3. Install the snap ring using a snap ring expander. Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
  
  Fig 109: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
  - Do not expand the snap ring excessively.
4. Set the end gap of the snap ring in the piston shown in the illustration.
  NOTE: Do not align the end gap of the snap ring with any of the stoppers.
  
  Fig 110: Identifying Stopper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD MULTIPLE DISC CLUTCH DISC
1. Install the 5 plates, 5 discs and flange.
  Install in order:
  
  P - D - P - D - P - D - P - D - P - D - F
  
  HINT:
  
  P = Plate
  
  D = Disc
  
  F = Flange
  
  Fig 111: Identifying Forward Multiple Disc, Plate And Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the snap ring.
3. Check that the end gap of the snap ring is not aligned with one of the cutouts.
INSPECT PACK CLEARANCE OF FORWARD CLUTCH (See INSPECTION )
INSPECT FORWARD MULTIPLE DISC CLUTCH DISC (See INSPECTION )

Fig 112: Installing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FORWARD CLUTCH ASSEMBLY

Install the thrust bearing to the forward clutch.

Standard Thrust Bearing Diameter

STANDARD BEARING AND DIAMETER CHART

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Bearing	33.85 (1.333)	52.2 (2.055)

NOTE: Install the thrust bearing properly so that the race "B" will be visible.

Fig 113: Position Of Installing Forward Clutch Assembly

Install the forward clutch to the multiple clutch hub.
NOTE: Align the splines of all discs in the forward clutch with those of the multiple clutch hub to assemble them securely.

Fig 114: Installing Forward Clutch To Multiple Clutch Hub
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL OVERDRIVE BRAKE GASKET
1. Install 2 new overdrive brake gaskets.
  
  Fig 115: Removing/Installing Overdrive Brake Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL GEAR ASSEMBLY
1. Install the differential gear to the transaxle.
Fig 116: Removing/Installing Differential Gear Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE
1. Install the thrust bearing underdrive race to the underdrive planetary gear.
Fig 117: Identifying No. 2 Thrust Bearing Underdrive Race
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL THRUST NEEDLE ROLLER BEARING

Calculate the end play value using the following formula and values of Dimensions D and E that were measured when installing the cylindrical roller bearing and underdrive planetary gear. Select and install the appropriate bearing race to satisfy the specified end play value.

Fig 118: Identifying Thrust Needle Roller Bearing

HINT:

End play = Dimension E - Dimension D - thrust bearing thickness 3.28 mm (0.1291 in.) - bearing race thickness.

End play:

0.50 to 0.99 mm (0.0196 to 0.0389 in.)

Standard Race Thickness

STANDARD THICKNESS CHART

E - D (mm (in.))	Thickness (mm (in.))
Less than 7.64 (0.3008)	3.5 (0.138)
7.64 (0.3008)	3.8 (0.150)

Standard Bearing and Bearing Race Diameter

STANDARD BEARING DIAMETER CHART

Item	Inside (mm (in.))	Outside (mm (in.))
Bearing	57.2 (2.252)	84.96 (3.3449)
Bearing Race	56.4 (2.220)	83.0 (3.268)

INSTALL OIL PUMP ASSEMBLY
1. Install the oil pump to the transaxle with the 7 bolts.
  Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)
  
  Fig 119: Locating Oil Pump Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the O-ring of the oil pump with ATF.
Fig 120: Identifying Oil Pump O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE HOUSING
1. Remove any packing material and be careful not to get oil on the contact surface of the transaxle housing.
2. Apply FIPG to the transaxle.
  FIPG:
  
  Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
  
  Fig 121: Identifying FIPG On Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the transaxle housing to the transaxle with the 18 bolts.
  Torque: Bolt A and D
  
  22 N*m (225 kgf*cm, 16 ft.*lbf)
  
  Bolt B and C
  
  29 N*m (300 kgf*cm, 22 ft.*lbf)
  
  Bolt E
  
  10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 122: Identifying Transaxle Housing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Each bolt length is indicated below.
  
  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 (2.834 in.)
  
  Bolt E 50 mm (1.969 in.)
  
  NOTE: Because the bolts labeled A are seal bolts, apply FIPG to new bolts and tighten them within 10 minutes after application.
  
  FIPG:
  
  Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
INSTALL NO. 1 TRANSAXLE CASE PLUG
1. Install 2 new O-rings to the 2 plugs.
2. Install the 2 plugs to the transaxle housing.
  Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
INSPECT INPUT SHAFT END PLAY (See INSPECTION )

Fig 123: Identifying No. 1 Transaxle Case Plug And O-Rings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SECURE AUTOMATIC TRANSAXLE ASSEMBLY
1. Secure the automatic transaxle assembly on wooden blocks.
  
  Fig 124: Securing Automatic Transaxle Assembly On Wooden Blocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
1. Coat a new oil seal with ATF.
2. Install the oil seal to the transaxle.
Fig 125: Identifying Manual Valve Lever Shaft Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PARKING LOCK ROD SUB-ASSEMBLY
1. Install the parking lock rod to the manual valve lever.
Fig 126: Installing Parking Lock Rod Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY
1. Install a new spacer and manual valve lever shaft to the transaxle.
  
  Fig 127: Installing Manual Valve Lever Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch and hammer, tap in a new pin.
  
  Fig 128: Tapping Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn the spacer and the lever shaft to align the smaller hole of 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 129: Staking Spacer Using Pin Punch
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING
1. Using needle-nose pliers, install the retainer spring.
Fig 130: Installing Manual Valve Lever Shaft Retainer Spring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PARKING LOCK PAWL BRACKET
1. Install the parking lock pawl bracket with the 2 bolts.
  Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
  
  Bolt length:
  
  25 mm (0.984 in.)
  
  Fig 131: Identifying Parking Lock Pawl Bracket With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY
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.
  
  Fig 132: Locating Manual Detent Spring Sub-Assembly With Mounting Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: Bolt A
  
  20 N*m (204 kgf*cm, 15 ft.*lbf)
  
  Bolt B
  
  12 N*m (122 kgf*cm, 9 ft.*lbf)
  
  HINT:
  
  Each bolt length is indicated below.
  
  Bolt A 27 mm (1.063 in.)
  
  Bolt B 16 mm (0.630 in.)

INSTALL B-3 ACCUMULATOR PISTON

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

Fig 133: Locating B-3 Accumulator Piston O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the 2 springs to the transaxle.

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

Fig 134: Identifying Transaxle Springs

Standard Accumulator Spring Length and Diameter

SPRING LENGTH SPECIFICATION

Spring	Free Length Outer Diameter (mm (in.))	Color
B-3 Inner	60.24 (2.3716) 15.9(0.626)	Yellowish green
B-3 Outer	74.61 (2.9374) 21.7 (0.854)	Blue

INSTALL C-1 ACCUMULATOR PISTON

Coat 2 new O-rings with ATF, and install them to the C-1 accumulator piston.

Fig 135: Locating C-1 Accumulator Piston O-rings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the spring to the transaxle.

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

Standard Accumulator Spring Length and Diameter

SPRING LENGTH SPECIFICATION

Spring	Free Length Outer Diameter (mm (in.))	Color
C-1	81.53 (3.2098) 18.5 (0.728)	Pink

Fig 136: Installing Spring To Transaxle

INSTALL C-3 ACCUMULATOR PISTON

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

Fig 137: Identifying C-3 Accumulator Piston O-ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard Accumulator Spring Length and Diameter

SPRING LENGTH SPECIFICATION

Spring	Free Length Outer Diameter (mm (in.))	Color
C-3	90.49 (3.5626) 19.2 (0.756)	White

Fig 138: Coating Piston With ATF

Install the spring to the C-3 accumulator piston.

Fig 139: Identifying C-3 Accumulator Spring

INSTALL CHECK BALL BODY
1. Install the check ball body and spring.
Fig 140: Identifying Check Ball Body And Spring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE DRUM GASKET
1. Coat a new brake drum gasket with ATF, and install it to the transaxle case.
Fig 141: Locating Brake Drum Gasket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
1. Coat a new transaxle case 2nd brake gasket with ATF, and install it to the transaxle case.
Fig 142: Locating Transaxle Case 2nd Brake Gasket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 GOVERNOR APPLY GASKET
1. Coat a new No. 1 governor apply gasket with ATF, and install it to the transaxle case.
Fig 143: Locating No. 1 Governor Gasket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION WIRE
1. Coat a new O-ring with ATF, and install it to the transmission wire.
  
  Fig 144: Identifying Transmission Wire O-Ring
  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 145: Locating Transmission Wire Retaining Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION VALVE BODY ASSEMBLY
1. Align the groove of the manual valve with the pin of lever.
2. Install the 17 bolts.
  
  Fig 146: Identifying Transmission Valve Body Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
  NOTE:
  - Push the valve body against the accumulator piston spring and the check ball body to install it.
  - Tighten the bolts marked by * in the illustration first temporarily because they are positioning bolts.
  HINT:
  
  Each bolt length is indicated below.
  
  Bolt length:
  
  Bolt A 25 mm (0.984 in.)
  
  Bolt B 41 mm (1.614 in.)
  
  Bolt C 45 mm (1.771 in.)
3. Connect the 5 solenoid connectors.
4. Coat the O-ring of the temperature sensor with ATF.
5. Install the ATF temperature sensor with the lock plate and bolt.
  Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf)
  
  Fig 147: Identifying Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE BODY OIL STRAINER ASSEMBLY
1. Coat a new O-ring with ATF.
2. Install the O-ring to the oil strainer.
  
  Fig 148: Locating Oil Strainer O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the oil strainer with the 3 bolts.
  Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
  
  Fig 149: Locating Oil Strainer Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY
1. Install the 3 magnets to the oil pan.
2. Apply adhesive or equivalent to the 18 bolts.
  Adhesive:
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
  
  NOTE: Since the bolts are seal bolts, apply adhesive to the bolts and tighten them within 10 minutes of application.
  
  Fig 150: Identifying Automatic Transaxle Oil Pan Sub-Assembly Magnets And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a new gasket, install the oil pan to the transaxle case with the 18 bolts.
  Torque: 7.6 N*m (77 kgf*cm, 67 in.*lbf)
  
  Fig 151: Securing Transaxle Assembly Onto Wooden Blocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 TRANSAXLE CASE PLUG
1. Coat 4 new O-rings with ATF, and install them to the 4 plugs.
2. Install the 4 plugs to the transaxle case.
  Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
  
  Fig 152: Identifying Transaxle Case Plugs And O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPEED SENSOR
1. Coat 2 new O-rings with ATF, and install them to the 2 speed sensors.
2. Install the 2 speed sensors with the 2 bolts.
  Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
  
  Fig 153: Identifying Speed Sensor Bolts And O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL COOLER INLET TUBE UNION
1. Coat a new O-ring with ATF, and install it to the union.
2. Install the union to the transaxle.
  Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf)
  
  Fig 154: Identifying Oil Cooler Inlet Tube Union And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL COOLER OUTLET TUBE UNION
1. Coat a new O-ring with ATF, and install it to the union.
2. Install the union to the transaxle.
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
INSTALL BREATHER PLUG HOSE

Fig 155: Identifying Oil Cooler Outlet Tube Union And O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
1. Install the park/neutral position switch to the manual valve shaft.
2. Temporarily install the 2 bolts.
3. Install a new lock plate and tighten the manual valve shaft nut.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  Fig 156: Locating Park/Neutral Position Switch Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily install the control shaft lever.
  
  Fig 157: Identifying Control Shaft Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Turn the lever counterclockwise until it stops, and then turn it clockwise 2 notches.
6. Remove the control shaft lever.
  
  Fig 158: Removing Control Shaft Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Align the groove with the neutral basic line.
8. Hold the switch in this position and tighten the 2 bolts.
  Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
  
  Fig 159: Identifying Switch Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Using a screwdriver, stake the nut with the lock plate.
  
  Fig 160: Staking Nut With Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Install the control shaft lever with the washer and nut.
  Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
  
  Fig 161: Locating Control Shaft Lever Nut
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