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Home >> Geo >> 1993 >> Prizm Base, Automatic >> Repair and Diagnosis (Single Page) >> Transmission >> Automatic Trans >> Overhaul - A-240 "E" & "L" Series >> Transaxle Reassembly >> A-243L, A-241E & A-244E Models

A-243L, A-241E & A-244E Models

NOTE: Coat all oil seal rings, discs, plates, rotating parts and sliding surfaces with ATF prior to reassembly. Use petroleum jelly to hold parts in place. Discs should be soaked in ATF for 15 minutes prior to installation.
NOTE: For bearing race and thrust bearing specifications and location, see Fig 13.
  1. Install oil tube apply cover and gasket. Install oil tubes. Install oil tube clamps. Install underdrive brake accumulator piston and spring. See Figure.
  2. Install oil gallery cover and gasket. Tighten bolts to 89 INCH lbs. (10 N.m). Apply thread sealant to screws for oil gallery cover. Install screws and tighten.
  3. Install cam guide bracket. Install parking lock rod in guide bracket. Install parking lock sleeve with raised portion up. Install stopper plate on raised portion of lock sleeve. Install guide sleeve and spring. Install parking lock pawl, pawl shaft and shaft clamp. See Figure.
  4. Install NEW "O" rings on 1st and reverse brake piston. Lubricate "O" rings with ATF. Using appropriate compressor, press 1st and reverse brake piston into transaxle case.
  5. Install piston return spring and snap ring. Avoid bending spring retainer by overtightening bolt. See Figure. Ensure snap ring is fully seated and centered by 3 lugs on spring retainer. Ensure end gap of snap ring is not aligned with spring retainer claw.
  6. Install underdrive brake piston "O" rings. Coat "O" rings with ATF. Install piston in transaxle case with cup side upward. Use care not to damage "O" rings. Install brake piston return spring. Install plates and discs. Start with plate and alternate with disc ending with disc. Install flange with flat end down.
  7. Using appropriate compressor, compress return spring. Install snap ring. Ensure snap ring end gap is not aligned with cutout. Using compressed air, confirm underdrive brake piston moves smoothly. See Figure. Install oil seal rings to transaxle case.
  8. Install underdrive one-way clutch assembly. Install anti-rattle clip. Align clutch disc tabs and install underdrive clutch assembly. Check operation of underdrive one-way clutch. Clutch should turn freely counterclockwise and lock clockwise. See Fig 1.
    Fig 1: Checking Underdrive Clutch Operation
    G95D19706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. Measure clutch assembly height from sleeve to inner race. Height should be .681-.717" (17.29-18.21 mm). See Fig 2. Check underdrive clutch piston stroke. Position dial indicator stem on underdrive clutch assembly. See Fig 3. Apply compressed air to oil passage in transaxle case. See Figure.
  10. For A-241E and A-243L transaxles, piston stroke should be .048-.061" (1.21-1.55 mm). For A-244E transaxles, piston stroke should be .059-.073" (1.50-1.86 mm). If piston stroke is not within specification, install correct flange.
  11. Flanges are available in thicknesses of .080" (2.04 mm) and .094" (2.40 mm) for A-244E. Flanges for A-241E and A-243L transaxle are available in thicknesses of .091" (2.30 mm), .098" (2.50 mm) and .106" (2.70 mm) . Install thrust bearing "G". See Fig 13. Install sun gear in transaxle case.
  12. Align clutch disc tabs in underdrive clutch. Install countershaft assembly. Check countershaft height. Measure distance from tip of countershaft to bolt seat of clutch support. See Fig 4. Countershaft height should be 1.311-1.398" (33.30-35.50 mm).
  13. Install thrust bearing "F". See Fig 6. Press in counterdriven gear. Install NEW lock nut. Using holder and adapter, tighten lock nut to 116 ft. lbs. (157 N.m). Using a dial indicator, measure countershaft end play. End play should be .009-.035" (.23-.89 mm). Stake lock nut. Install snap ring in transaxle case.
  14. Install intermediate shaft. Apply gasket sealer to rear cover sealing areas. Install transaxle rear cover and bolts. Ensure bolts are installed in correct locations. See Fig 5. Tighten bolts to 21 ft. lbs. (29 N.m). Install apply gaskets in transaxle case. Install thrust washer and governor driven gear. See Figure. Ensure intermediate shaft rotates smoothly.
    Fig 2: Measuring Underdrive Clutch Assembly Height
    G95E19707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 3: Measuring Underdrive Clutch Piston Stroke
    G95F19708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 4: Measuring Height Of Countershaft
    G95G19709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 5: Identifying Transaxle Rear Cover Bolts
    G93J25626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. Install 1st and reverse brake components in transaxle case. Install inner flange with flat end facing upward. Install discs and plates. Start with disc, alternate with plate, ending with disc. Install outer flange with flat area facing inward. Install snap ring in groove. Ensure end gap does not align with transaxle case cutout.
  16. Check 1st and reverse brake operation. Apply light air pressure to oil passage. See Figure. Ensure piston moves smoothly. Install thrust bearing and races "A" in rear planetary ring gear. See Fig 13. Align disc tabs. Install rear planetary ring gear in transaxle case. Install thrust washer on rear planetary gear. Ensure tabs align with grooves of gear.
  17. Align spline of planetary gear with tabs of 1st and reverse brake discs. Install rear planetary gear into 1st and reverse brake. Ensure inner surface of rear planetary gear is below upper surface of flange. See Fig 6. Install No. 2 one-way clutch with shiny side upward. Rotate planetary gear clockwise while installing No. 2 one-way clutch.
  18. Check No. 2 one-way clutch operation. Planetary gear should rotate clockwise and lock counterclockwise. See Fig 7. Install thrust washer on planetary gear. Install snap ring. Ensure end gap of snap ring is not aligned with case cutouts.
  19. Install 2nd brake flange with flat end facing upward. Install discs and plates, starting with disc, alternating with plate and ending with plate. Install piston return spring assembly with springs over case protrusions. Install 2nd coast brake band guide with tip contacting transaxle case. Align 2nd brake drum groove with bolt in transaxle case.
  20. Install 2nd brake drum. Install snap ring in groove while compressing piston return springs with hammer handles. Ensure end gap of snap ring is not aligned with transaxle case cutouts. Install 2nd brake drum gasket in center oil passage until it contacts 2nd brake drum. Apply compressed air into 2nd brake oil passage in transaxle case. Ensure 2nd brake piston operates smoothly. See Figure.
  21. Align 2nd brake disc tabs. Install No. 1 one-way clutch and 2nd brake hub. Check distance between surface of 2nd brake hub and rear planetary gear. See Fig 8. Distance should be approximately .20" (5.0 mm). Install thrust washer on sun gear input drum. Install sun gear and sun gear input drum. Rotate sun gear clockwise while installing gear into one-way clutch.
  22. Install thrust bearing and race "B" on front planetary gear. See Fig 6. Install planetary gear. Install thrust bearing and race "C" on front planetary ring gear. See Fig 13. Install front planetary ring gear. Install intermediate shaft oil seal ring.
  23. If components installed in transaxle case are correctly installed, end of ring gear flange bushing will be even or slightly lower than intermediate shaft shoulder. See Fig 9. Install thrust bearing and races "D" on tip of ring gear flange. Install 2nd coast brake band into transaxle case. Install pin through oil pump mounting bolt hole.
  24. Install thrust bearing and race "E" on forward clutch drum. See Fig 13. Install clutch drum thrust washer on direct clutch drum with oil groove facing upward. Align clutch disc tabs. Install direct clutch into forward clutch. If tabs are aligned with hub correctly, end of direct clutch drum bushing will be flush with surfaces of forward clutch.
  25. Rotate forward clutch to mesh with front planetary gear and discs. Install direct clutch and forward clutch into transaxle case. Check installation of direct/forward clutch assembly. Measure distance between direct clutch and sun gear drum (shell). See Fig 10. Distance should be .118" (3.0 mm).
  26. Install differential. Apply gasket sealer (Loctite 518 or equivalent) to transaxle housing. Install transaxle housing. Install mounting bolts in original locations. See Figure. Tighten bolts to 21 ft. lbs. (29 N.m). Check differential side bearing preload. Refer to DIFFERENTIAL  under COMPONENT DISASSEMBLY & REASSEMBLY.
  27. Install race on stator shaft. Install "O" ring on oil pump. Install oil pump. Hold input shaft and tightly press oil pump body to slide oil seal rings on stator shaft through direct clutch drum. Install and tighten bolts to 18 ft. lbs. (25 N.m).
    Fig 6: Checking Rear Planetary Installation
    G95J19710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 7: Checking No. 2 One-Way Clutch Operation
    G95A19711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 8: Checking 2nd Brake Hub Installation
    G95B19712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 9: Checking Front Planetary Ring Gear Installation
    G95C19713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 10: Checking Direct/Forward Clutch Drum Assembly Installation
    G95D19714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: DO NOT  apply excessive pressure on oil pump. Seal rings will stick to direct clutch drum if excessive pressure is used.
  28. Ensure input shaft rotates smoothly. Using a dial indicator, measure input shaft end play. End play should be .012-.035" (.30-.90 mm). Replace oil pump race if end play is incorrect. Oil pump races are available in thicknesses of .031" (.80 mm) and .055" (1.40 mm).
  29. Install spring, 2nd coast brake piston and cover into bore. Install snap ring. Ensure front end of piston rod contacts center of 2nd brake band depression.
  30. Measure 2nd coast brake piston stroke by applying compressed air to oil passage in transaxle case. See Figure. Piston stroke should be .059-.118" (1.50-3.00 mm). Replace band if stroke is not within specification.
  31. Recheck piston stroke after band. Coat accumulator piston "O" rings with ATF. Install "O" rings on accumulator pistons. Measure spring free length and replace as necessary.
  32. See appropriate ACCUMULATOR SPRING SPECIFICATIONS table. Install pistons and springs in transaxle case. See Fig 11. Install accumulator cover and NEW gasket. Tighten bolts to 89 INCH lbs. (10 N.m).
    ACCUMULATOR SPRING SPECIFICATIONS (A-241E, A-243L & A-244E)

    Application Color Free Length: In. (mm)
    A-243L (1)
    Direct Clutch Blue/Lt. Blue 2.817 (71.54)
    Forward Clutch - Inner Spring None 1.673 (42.50)
    Forward Clutch - Outer Spring None 3.063 (77.80)
    Underdrive Clutch White 2.420 (61.47)
    2nd Brake Yellow 2.231 (56.68)
    A-241E (1)
    Direct Clutch - No. 1 Spring Pink 610 (15.50)
    Direct Clutch - No. 2 Spring Pink 462 (62.54)
    Forward Clutch - Inner Spring Pink 614 (41.00)
    Forward Clutch - Outer Spring Pink 917 (74.10)
    Underdrive Clutch Purple 2.397 (60.88)
    2nd Brake - No. 1 Spring Green .610 (15.50)
    2nd Brake - No. 2 Spring Green 2.397 (60.88)
    A-244E (1)
    Direct Clutch Red/White 2.446 (62.12)
    Forward Clutch - Inner Spring None 1.457 (37.00)
    Forward Clutch - Outer Spring None 3.063 (77.80)
    Underdrive Clutch Yellow 2.231 (56.68)
    2nd Brake Blue 2.314 (58.77)
    (1) For accumulator spring locations, see Fig 11.
    Fig 11: Identifying Accumulator Pistons & Springs
    G95E19715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. Install 2nd brake apply gasket. Install throttle cable. Use care not to damage "O" ring. Ensure cable is fully seated in transaxle case. Install solenoid wire(s) in transaxle case. Install VALVE BODY assembly. See VALVE BODY ASSEMBLY R & I  under ON-VEHICLE SERVICE. Ensure proper length bolt is installed in proper location. Connect solenoid wiring.
  34. Install manual detent spring and cover. Install bolt and tighten bolt to 89 INCH lbs. (10 N.m). Ensure manual valve lever is in contact with center of roller at tip of detent spring. Install oil tubes. Install oil tube clamp and bracket. Tighten bolts to 89 INCH lbs. (10 N.m). Install oil strainer (filter) with NEW gasket.
  35. Install magnet(s) in oil pan. Install NEW oil pan gasket and install oil pan. Tighten oil pan bolts to 43 INCH lbs. (4.9 N.m). Install speed sensor and sensor rotor (if equipped). Install NEW "O" ring on sensor cover and install cover. Install sensor bracket and tighten bolts to 115 INCH lbs. (13 N.m).
  36. On A-243L transaxles, install governor oil strainer. Install NEW gasket to governor body adapter. Install governor body adapter, governor body and thrust washer. Install NEW "O" ring on cover. Install cover and cover brackets. Tighten bracket bolts to 115 INCH lbs. (13 N.m). Install throttle cable and solenoid lock plates.
  37. On all transaxles, install oil cooler pipe unions (if necessary). Install park/neutral position switch to manual valve shaft. Install packing, nut, stopper and nut. Tighten nut to 61 INCH lbs. (6.9 N.m). Adjust park/neutral position switch (if necessary) and tighten adjusting bolts to 48 INCH lbs. (5.4 N.m). See appropriate TRANSMISSION SERVICING - A/T article in the AUTOMATIC TRANS SERVICING section. Stake nut to stopper. Install manual shift lever and tighten nut. Install filler tube and dipstick. Install oil cooler pipes.
  38. Install torque converter on transaxle. Using a straightedge and calipers, measure torque converter installed depth. For torque converter depth specifications, see TORQUE CONVERTER DEPTH SPECIFICATIONS . See Fig 12.
TORQUE CONVERTER DEPTH SPECIFICATIONS

Application In. (mm)
Celica .898 (22.80)
MR2 .906 (23.00)
Paseo .528 (13.40)
Fig 12: Measuring Torque Converter Depth
G93D25661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 13: Identifying Bearing Race & Thrust Bearing Locations
G93B25628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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