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Home >> Toyota >> 1993 >> Paseo Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 61 (Overhaul - A-241E/H/L & A-243E) >> Transaxle Reassembly >> Overhaul - A-241E/H/L & A-243E >> Reassembly (A-241H)

Reassembly (A-241H)

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  1. Using Bearing Installer (09351-32140), press bearing in transaxle housing. Install bearing stopper. Install oil tube apply cover, gasket and strainer. Install oil tubes. Install oil tube clamps. Press bearing in transaxle case. Install underdrive brake accumulator piston and spring.
  2. Install parking lock rod to manual valve lever. Install manual shaft, washer, spacer and lever. Install retaining spring. Ensure washer is located between retaining spring and case. Install pin. Stake spacer in proper position. Install cam guide bracket.
  3. 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.
  4. Install underdrive brake piston "O" rings. Coat "O" rings with ATF. Install piston in case with cupped side upward. Use care not to damage "O" rings. Install brake piston return spring. Install 3 plates and 3 discs. Start with plate and alternate with disc ending with disc. Install flange with flat end up.
  5. Using Spring Compressor (09351-32070), 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. Install oil seal rings to transaxle case.
  6. Install underdrive one-way clutch assembly. Install anti-rattle clip. Align clutch disc tabs. Install underdrive clutch assembly. Check operation of underdrive one-way clutch. Clutch should turn freely counterclockwise and lock clockwise.
  7. Check clutch assembly height from sleeve to inner race. Height should be .681-.717" (17.29-18.21 mm). Using Dial Indicator (09351-32190), check piston stroke of underdrive clutch. Apply compressed air to activate clutch piston. See Fig 1. Piston stroke should be .0591-.0732" (1.500-1.860 mm). If piston stroke is not within specification, ensure assembly order is correct. Flange is available in 2 thicknesses: .0803" (2.040 mm) and .0945" (2.400 mm). Replace if necessary.
    Fig 1: Checking Underdrive Clutch Operation
    G93G25797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. Install thrust bearing and race. Bearing facing upward. Bearing outer diameter should be 1.72" (43.7 mm) and inner diameter should be 1.22" (31.0 mm). Install sun gear snap ring. Install sun gear to case.
  9. Align clutch disc tabs. Install countershaft assembly. Check countershaft height. Measure distance from tip of countershaft to bolt seat of clutch support. Countershaft height should be 1.311-1.398" (33.30-35.50 mm).
  10. Install needle thrust bearing. Bearing outer diameter is 2.272" (57.70 mm) and inner diameter is 1.614" (41.00 mm). Using Bearing Replacer (09351-32100) and Seal Replacer (09351-32140) with an arbor press, install counter driven gear. Install new lock nut. Using holder and adapter, tighten lock nut to 116 ft. lbs. (157 N.m). Check end play of countershaft with dial indicator. End play should be .0091-.0350" (.231-.889 mm). Stake lock nut.
  11. Install 1st and reverse brake in case. Install inner flange with flat end facing upward. Install 6 discs and 5 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 case cutout. Using compressed air, confirm 1st and reverse brake piston moves smoothly. See Fig 2.
    Fig 2: Checking 1st & Reverse Brake Operation
    G93H25798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. Install snap ring in transaxle case. Install intermediate shaft. Apply Loctite (518) to rear cover sealing areas. Tighten bolts to 22 ft. lbs. (29 N.m). Install thrust washer and governor driven gear. Install new apply gaskets or oil seals in transaxle case. Ensure intermediate shaft rotates smoothly.
  13. Align clutch disc tabs. Install rear planetary ring gear. Align clutch disc tabs. Install rear planetary gear. Install No. 2 one-way clutch with shiny side upward. Rotate planetary gear clockwise while installing one-way clutch.
  14. Check one-way clutch operation. Planetary gear should rotate clockwise and lock counterclockwise. Install snap ring. Ensure end gap is not aligned with case cutouts.
  15. Install 2nd coast brake band guide with tip contacting case. Install 2nd brake flange with flat end facing upward. Install 3 discs and 3 plates, starting with a disc, alternating with a plate and ending with a plate.
  16. Install piston return spring assembly with springs over case protrusions. Align 2nd brake drum groove with bolt in case. Install 2nd brake drum.
  17. Install snap ring in groove while compressing piston return springs with hammer handles. Ensure end gap is not aligned with case cutouts. Apply compressed air into 2nd brake oil passage in case nearest manual valve shaft. Ensure piston movement.
  18. Install 2nd brake drum gasket in center oil passage until it contacts 2nd brake drum. 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. Distance should be approximately .20" (5 mm).
  19. While turning sun gear, sun gear input drum and thrust washer clockwise, install into No. 1 one-way clutch. Install bearings and races on planetary gear. Install front planetary gear. Refer to the FRONT PLANETARY GEAR BEARING & RACE SPECIFICATIONS  table.
    FRONT PLANETARY GEAR BEARING & RACE SPECIFICATIONS

    Part Inner Diameter In. (mm) Outer Diameter In. (mm)
    Planetary Gear
    Race 1.102 (28.00) 1.772 (45.00)
    Bearing 1.181 (30.00) 1.772 (45.00)
    Planetary Ring Gear
    Front Race .866 (22.00) 1.492 (37.90)
    Bearing .874 (22.20) 1.421 (36.10)
    Rear Race .748 (19.00) 1.378 (35.00)
    Ring Gear Flange
    Front Race .866 (22.00) 1.492 (37.90)
    Bearing .874 (22.20) 1.421 (36.10)
    Rear Race .906 (23.00) 1.406 (35.70)
  20. Install front planetary ring gear. If correctly installed, end of ring gear flange bushing will be even with intermediate shaft. Install thrust bearing and races on tip of ring gear flange. Install 2nd coast brake band. Install pin through oil pump mounting bolt hole.
  21. Install bearing and race on forward clutch drum. Install direct clutch drum thrust washer with oil groove upward on clutch drum. Align clutch disc tabs. Mesh hub with tabs of direct clutch while rotating clutch drum or forward clutch. While rotating forward clutch to mesh front planetary ring gear and discs, install direct clutch and forward clutch. Direct clutch is properly installed when clutch drum bushing is even with thrust bearing on forward clutch.
  22. Install differential. Apply seal packing Loctite (518) to transaxle housing. Install and tighten bolts to 21 ft. lbs. (29 N.m). Check differential side bearing preload. See DIFFERENTIAL ASSEMBLY . (A-241H).
    NOTE: DO NOT  apply excessive pressure on oil pump. Seal rings will stick to direct clutch drum if excessive pressure is used.
  23. Install oil seal rings. Install race on stator shaft. Race outer diameter is 1.693" (43.00 mm). Race inner diameter is 1.201" (30.50 mm). Install "O" ring on oil pump. Install oil pump. Hold input shaft and lightly 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).
  24. Measure input shaft end play in axial direction using a dial indicator. End play should be .012-.035" (.39-.90 mm). Change oil pump race if end play is incorrect. Oil pump races are available in thicknesses of .031" (.80 mm) and .055" (1.40 mm). Ensure input shaft rotates smoothly.
  25. Install "O" rings on cover. Install 2nd coast brake piston, spring and cover into bore. Install snap ring while pressing cover. Ensure front end of piston rod contacts center of 2nd brake band depression.
  26. Apply small amount of paint to piston rod at point rod meets case. Using Wire Gauge (09240-00020), measure piston stroke using compressed air. Piston stroke is .059-.118" (1.50-3.00 mm). If travel exceeds specification, replace 2nd coast brake band.
  27. Install accumulator pistons and springs. See Fig 3. Coat the accumulator piston "O" rings with ATF. Install "O" rings. Install the pistons and springs. Install the accumulator cover and gasket. Tighten retaining bolts to 89 INCH lbs. (10 N.m). Refer to the ACCUMULATOR SPRING FREE LENGTH SPECIFICATIONS  table.
    ACCUMULATOR SPRING FREE LENGTH SPECIFICATIONS

    Application (Spring) Color Free Length In. (mm)
    Forward Clutch Outer Pink 2.917 (74.10)
    Forward Clutch Inner Pink 1.614 (41.00)
    Direct Clutch Blue 2.606 (66.20)
    2nd Brake No. 1 White 1.437 (36.50)
    2nd Brake No. 2 Yellow 2.232 (56.70)
    Underdrive Clutch Light Green 2.445 (62.10)
    Fig 3: Exploded View Of Accumulator Pistons & Springs
    G93I25799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. Install 2nd brake apply gasket. Install throttle cable. Use care not to damage "O" ring. Ensure cable is fully seated in case. DO NOT  roll case over cable. Install solenoid in case.
  29. Install valve body. See CONTROL VALVE ASSEMBLY  under ON-VEHICLE SERVICE. Ensure proper length bolt is installed in proper location.
  30. Connect solenoid connector. Install manual detent spring and cover. Hand tighten bolt, then tighten to 89 INCH lbs. (10 N.m). Ensure manual lever is in contact with center of roller at tip of detent spring.
  31. Install oil tubes with a plastic hammer. DO NOT  bend or damage tubes. Install oil tube clamp and bracket. Tighten bolts to 89 INCH lbs. (10 N.m). Install oil strainer. Tighten bolts to 89 INCH lbs. (10 N.m). Install magnets in oil pan. Ensure magnets do not interfere with oil tubes. Install oil pan with a new gasket. Tighten bolts to 89 INCH lbs. (10 N.m).
  32. Install governor oil strainer to case. Install gasket, governor body adapter, governor body and thrust washer. Install "O" ring on cover. Install cover to case. Install cover brackets. Tighten bolts to 115 ft. lbs. (13 N.m).
  33. Install neutral start switch to manual valve shaft. Install packing. Install nut and lock stopper. Tighten nut to 61 INCH lbs. (6.9 N.m). Temporarily install manual shift lever. Turn lever counterclockwise until lever stops. Turn lever clockwise 2 notches. Remove manual shift lever. Align groove and neutral basic line. Install and tighten bolts to 48 INCH lbs. (5.4 N.m). Using a screwdriver, stake nut with nut stopper. Install manual shift lever with washer. Tighten nut to 115 INCH lbs. (13 N.m).
  34. Install filler tube and transmission dipstick. Install oil cooler pipes. Tighten to 25 ft. lbs. (34 N.m). Install differential side gear intermediate shaft. Install new snap ring to shaft groove. Using a plastic hammer, install shaft. Keeping shaft on differential pinion shaft, measure protrusion length. Protrusion length should be 10.0" (254 mm). Install new apply gasket to transfer left case.
  35. Install transfer assembly. Apply seal packing Three Bond (1131) to transfer. Install transfer assembly. Coat threads of bolts with sealer Three Bond (1324). Install and tighten bolts to 51 ft. lbs. (69 N.m). Inspect mode select lever position. After inspection, ensure mode select lever position is on FREE mode and attach lock bolt.
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