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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-245E & A-246E Models

A-245E & A-246E 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 at least 15 minutes prior to installation.
NOTE: For bearing race and thrust bearing specifications and location, see Figure.
  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. Place counterdrive on press platform with NEW spacer installed. Place case on gear. Press bearing onto counterdrive shaft until seated. Install intermediate shaft. Install lock nut. Secure counterdrive gear from turning and tighten lock nut to 130 ft. lbs. (177 N.m).
  9. Using INCH lb. torque wrench, measure starting torque of intermediate shaft at counterdrive gear lock nut. Starting torque for new bearings is 2.7-6.2 INCH lbs. (.3-.7 N.m). Starting torque for used bearings is 1.8-3.5 INCH lbs. (.2-.4 N.m).
  10. If starting torque is less than specification, replace spacer and recheck. Loosen lock nut it starting torque is greater than specification. Stake lock nut in place.
  11. 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 Figure.
  12. Measure clutch assembly height from sleeve to inner race. Height should be .681-.717" (17.29-18.21 mm). See Fig 1. Check underdrive clutch piston stroke. Position dial indicator stem on underdrive clutch assembly. See Figure. Apply compressed air to oil passage in transaxle case. See Figure.
  13. Piston stroke should be .059-.075" (1.50-1.90 mm). If piston stroke is not within specification, install correct flange. Flanges are available in thicknesses of .080" (2.04 mm), .091" (2.30 mm), .094" (2.40 mm) and .098" (2.50 mm). Install thrust bearing "G". See Figure. Install sun gear in transaxle case.
  14. 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 Figure. Countershaft height should be 1.193-1.280" (30.30-32.50 mm).
  15. Install thrust bearing "F". See Figure. Press in counterdriven gear. Install NEW lock nut. Using holder and adapter, tighten lock nut to 133 ft. lbs. (180 N.m). Using a dial indicator, measure countershaft end play. End play should be .009-.035" (.23-.89 mm). Stake lock nut.
  16. Apply gasket sealer to rear cover sealing areas. Install transaxle rear cover and bolts. Ensure bolts are installed in correct locations. See Fig 2. Tighten bolts to 84 INCH lbs. (10 N.m). Ensure intermediate shaft turns smoothly.
    Fig 1: Measuring Underdrive Clutch Assembly Height
    G95F19716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 2: Identifying Transaxle Rear Cover Bolts
    G95G19717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. Install 1st and reverse brake components in transaxle case. Install discs and plates. Start with plate, alternate with disc, 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.
  18. Check 1st and reverse brake clutch pack clearance. See Figure. Install thrust bearing and races "A" in rear planetary ring gear. See Figure. Align disc tabs. Install thrust washer on rear planetary gear. Ensure tabs align with grooves of gear.
  19. 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 Figure. Install No. 2 one-way clutch with shiny side upward. Rotate planetary gear clockwise while installing No. 2 one-way clutch.
  20. Check No. 2 one-way clutch operation. Planetary gear should rotate clockwise and lock counterclockwise. See Figure. Install thrust washer on planetary gear. Install snap ring. Ensure end gap of snap ring is not aligned with case cutouts.
  21. 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.
  22. 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.
  23. 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 Figure. 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.
  24. Install thrust bearing and race "B" on front planetary gear. See Figure. Install planetary gear. Install thrust bearing and race "C" on front planetary ring gear. See Figure. Install front planetary ring gear. Install intermediate shaft oil seal ring.
  25. 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 Figure. Install thrust bearing and races "D" on tip of ring gear flange. Install 2nd coast brake band into transaxle case. Install pin.
  26. Install thrust bearing and race "E" on forward clutch drum. See Figure. 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.
  27. 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 Figure. Distance should be .118" (3.0 mm).
  28. 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.
  29. 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 rod if stroke is not within specification. Rod lengths available are, 2.811" (71.4 mm) and 2.870" (72.9 mm). Install apply gasket in transaxle case.
  30. Install differential. Install apply tube if removed. 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. See DIFFERENTIAL  under COMPONENT DISASSEMBLY & REASSEMBLY.
  31. 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).
    NOTE: DO NOT  apply excessive pressure on oil pump. Seal rings will stick to direct clutch drum if excessive pressure is used.
  32. 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).
  33. Coat accumulator piston "O" rings with ATF. Install "O" rings on accumulator pistons. Measure spring free length and replace as necessary. See appropriate ACCUMULATOR SPRING SPECIFICATIONS table. Install pistons and springs in transaxle case. See Figure.
    ACCUMULATOR SPRING SPECIFICATIONS (A-245E & A-246E) (1)

    Application Color Free Length: In. (mm)
    Direct Clutch Blue 2.768 (70.30)
    Forward Clutch
    Inner Spring Red 1.437 (36.50)
    Outer Spring Red 2.480 (63.00)
    Underdrive Clutch
    Inner Spring Yellow 1.969 (50.00)
    Outer Spring - A-245E White 2.815 (71.50)
    Outer Spring - A-246E White 2.692 (68.40)
    2nd Brake Brown 2.547 (64.70)
    (1) For accumulator spring locations, see Figure.
    THRUST BEARING & RACE SPECIFICATIONS (A-245E & A-246E) (1)

    Application Outer Diameter: INCH (mm) Inner Diameter: INCH (mm)
    "A"
    Front Race 1.480 (37.6) .949 (24.1)
    Bearing 1.480 (37.6) .870 (22.1)
    "B" Bearing 1.772 (45) 1.106 (28.1)
    "C"
    Rear Race 1.378 (35) .748 (19)
    Bearing 1.496 (38.0) .866 (22.0)
    "D"
    Rear Race 1.555 (39.5) 1.024 (26)
    Bearing 1.654 (42.0) 1.016 (25.8)
    "E" Bearing 1.811 (46) 1.209 (30.7)
    "F" Bearing 2.283 (58.0) 1.614 (41)
    "G" Bearing 1.728 (43.9) 1.220 (31)
    "H"
    Front Race 1.646 (41.8) 1.181 (30)
    Bearing 1.728 (43.9) 1.220 (31)
    (1) For thrust bearing locations, see Figure.
  34. Install 2nd brake apply gasket. Install check ball body in passage next to 2nd brake accumulator. 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.
  35. 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.
  36. 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 throttle cable and solenoid lock plates.
  37. Install oil cooler pipe unions (if necessary). Install the park/neutral position switch to the manual valve shaft. Install packing, nut, stopper and nut. Tighten nut to 61 INCH lbs. (6.9 N.m). Adjust the park/neutral position switch (if necessary) and tighten adjusting bolts to 48 INCH lbs. (5.4 N.m). Refer to the appropriate TRANSMISSION SERVICING - A/T article in TRANSMISSION 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 Figure.
TORQUE CONVERTER DEPTH SPECIFICATIONS

Application In. (mm)
Celica 1.8L (1994) .898 (22.80)
Corolla .898 (22.80)
Prizm .906 (23.00)
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