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Home >> Toyota >> 1998 >> Avalon XLS >> Repair and Diagnosis (Single Page) >> Transmission >> Automatic Trans >> Automatic Transmission Overhaul - A-540E, A-540H & A-541E >> Overhaul >> Overdrive Unit Disassembly & Reassembly >> Reassembly (Overdrive Counter Drive Gear)

Reassembly (Overdrive Counter Drive Gear)

  1. Install snap ring in counter drive gear. Install 2 outer races to both sides of counter drive gear. Press in outer races until races touch snap ring.
  2. Install snap ring to ring gear. While pushing down on ring gear, squeeze snap ring end with needle-nose pliers. Install overdrive planetary ring gear into counter drive gear.
  3. Install rear bearing on shaft. Press in bearing until side surface of inner race touches planetary carrier. Install counter drive gear on shaft. Mesh ring gear with planetary pinions. Place front bearing on shaft. Hold ring gear to prevent shaft from falling.
  4. Press in bearing until there is slight play between bearings. Install intermediate shaft bearing. Press bearing until bearing slightly touches front bearing of counter drive gear.
  5. Place NEW locking washer and adjusting nut on intermediate shaft. Adjust preload of counter drive gear. Holding shaft in a soft-jawed vise and using a tension gauge and lock nut wrench on adjusting nut, tighten adjusting nut. See Fig 2.
  6. Rotate counter drive gear right and left several times before measuring preload. Tighten adjusting nut until preload is 2.1-3.4 lbs. (9.2-15.3 N). Bend locking washer tab until even with adjusting nut groove.
  7. Install 4 plugs into pinion shaft. Install No. 3 thrust washer with groove facing overdrive case. Install one-way clutch into outer race. Install retainers on both sides of one-way clutch. Install one-way clutch into overdrive planetary gear. Ensure one-way clutch is installed in correct direction. Install retaining plate and snap ring.
  8. Hold overdrive direct clutch and turn intermediate shaft. Shaft should turn freely clockwise and lock counterclockwise. See Fig 1. Remove overdrive direct clutch from one-way clutch.
  9. While turning overdrive planetary gear clockwise, install gear on overdrive direct clutch. If overdrive planetary gear is properly installed, clearance between counter drive gear and overdrive case will be .94" (24.0 mm). See Fig 3.
Fig 1: Checking OD One-Way Clutch Operation
G93C25777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 2: Checking Counter Drive Gear Preload
G93D25778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 3: Checking Distance Between Overdrive Gear & Case
G93E25779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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