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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 >> Transaxle Reassembly >> Reassembly (Transaxle)

Reassembly (Transaxle)

  1. Check operation of parking lock pawl. Ensure counter driven gear is locked when manual valve lever is in "P" range. Install "O" rings on 1st and reverse brake piston. Install 1st and reverse brake piston in case. Push piston into bore of case, facing spring seat upward.
  2. Install piston return spring. Using appropriate spring compressor, compress return spring. See Figure. Install snap ring. Ensure snap ring is fully seated and centered by 3 lugs on spring retainer. Ensure snap ring end gap is not aligned with spring retainer claw. Install center snap ring.
  3. Install overdrive brake and overdrive clutch apply gaskets over appropriate case opening (ports). Install overdrive brake drum to case. Install NEW case gasket. Align each bolt hole in gasket case. Install overdrive assembly over gasket to transaxle case. Coat threads of 23 mm bolts with sealer. See Fig 1. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
  4. Check intermediate shaft end play (axial). See Fig 2. End play should be .019-.059" (.47-1.50 mm). Ensure shaft turns smoothly. If end play is not within specification, check installation of intermediate shaft.
    NOTE: For thrust bearing and race location and identification, see Fig 8 and Fig 9 .
  5. Install rear planetary ring gear. Place bearing on ring gear. Coat thrust washer with petroleum jelly and install on rear planetary gear. Install rear planetary gear. See Figure.
  6. Install 1st and reverse brake discs, plates and flange. See Figure. Start with plate, alternating with disc, and ending with disc. Install outer flange with flat side facing toward piston side. Install snap ring. Ensure snap ring end-gap is not aligned with cutouts.
  7. Check operation of 1st and reverse brake. Apply compressed air at oil passage of transaxle case to confirm piston movement. See Figure. Check pack clearance of 1st and reverse brake. Clearance for A-540E is .33-.081" (.85-2.05 mm). Clearance for A-540H is .041-.085" (1.04-2.16 mm). Clearance for A-541E is .076-.106" (1.92-2.86 mm). See Fig 3.
  8. Install No. 2 one-way clutch in case. Install one-way clutch while turning planetary gear clockwise with snap ring expander. Check operation of No. 2 one-way clutch by turning planetary gear. Gear should turn freely clockwise and lock counterclockwise. See Fig 4. Install snap ring. Ensure end gap is not aligned with cutouts.
  9. Install thrust washer on rear planetary gear. Install 2nd coast brake band guide with correct bolt. Place thrust washer on No. 1 one-way clutch. Install No. 1 one-way clutch into rear planetary gear.
  10. Install 2nd brake flange with flat end facing up. Install 2nd brake discs and plates, starting with disc and ending with plate. Place piston return spring in case. Place 2nd brake drum in case. Ensure groove of drum is aligned with bolt. While compressing piston return springs over drum with hammer handles, install snap ring in groove. Ensure snap ring end gap is not aligned with cutouts.
  11. Install NEW 2nd brake gasket until contact is made with 2nd brake drum. See Figure. Check operation of 2nd brake by applying compressed air into oil passage. Make sure the piston moves freely. See Figure.
  12. Install thrust washer on sun gear input drum (shell). Install sun gear by turning clockwise and installing in No. 1 one-way clutch. Install oil seal ring to intermediate shaft. Install front planetary gear with bearing on both sides of gear on sun gear. Install front planetary ring gear onto sun gear.
  13. Install 2nd coast brake band into case. Install pin through oil pump mounting bolt hole. Install thrust bearings on both sides of forward clutch. Install thrust washer with oil groove facing upward onto direct clutch drum.
  14. Mesh hub of forward clutch with flukes of direct clutch discs. Ensure bearing and thrust washer do not move out of place. Install direct and forward clutch into case. Hold direct clutch toward forward clutch to prevent thrust washer from moving out of place. Check distance between direct clutch drum and sun gear input drum. See Fig 5. Distance should be .12" (3 mm).
    Fig 1: Locating Overdrive Assembly Bolts
    G93B25800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 2: Checking Intermediate Shaft End Play
    G93C25801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 3: Checking 1st & Reverse Brake Pack Clearance
    G93C25744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 4: Checking Operation Of No. 2 One-Way Clutch
    G95B19431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 5: Checking Direct Clutch & Sun Gear Drum Clearance
    G93H25806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. Place oil pump over input shaft. Align bolt holes of pump body with transaxle case. DO NOT push on oil pump hard, or oil seal ring may stick to direct clutch drum. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
  16. Measure end play of input shaft. See Fig 6. End play should be .010-.035" (.25-.90 mm) for A-540E and A-541E transaxles or .012-.035" (.30-.90 mm) for A-540H transaxle. If end play is not within specification, replace front bearing on forward clutch. Bearings are available in thicknesses of .142" (3.60 mm) and .165" (4.19 mm) for A-540E and A-541E transaxles or in thicknesses of .031" (.08 mm) and .055" (1.40 mm) for A-540H transaxle. Check input shaft rotation. Ensure shaft turns smoothly.
    Fig 6: Measuring Input Shaft End Play
    G93I25807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. Install 2nd coast brake piston. Install outer spring with piston. Place cover in bore. See Figure. Install snap ring while pressing in on cover. Ensure front end of piston rod contacts center of 2nd brake band depression.
  18. Check 2nd coast brake piston stroke. Apply mark to piston rod at point were piston rod contacts case. Measure 2nd coast piston stroke by applying and releasing 57-114 psi (4-8 kg/cm2 ) of compressed air. See Figure. Piston stroke should be .079-.138" (2.00-3.50 mm).
  19. If stroke exceeds specification, replace piston rod with longer rod. Piston rods are available in 2 sizes: 3.748" (95.20 mm) or 3.791" (96.30 mm). After installation of NEW rod, re-measure stroke. If stroke exceeds specification, replace brake band.
  20. Install accumulator pistons and springs in bores. See Figure. See ACCUMULATOR SPRING SPECIFICATIONS  table. Install accumulator cover with NEW gasket. Tighten bolts in crisscross pattern to specification.
    ACCUMULATOR SPRING SPECIFICATIONS

    Application Color Free Length - In. (mm)
    A-540E
    Direct Clutch Yellow/Purple 2.173 (55.20)
    2nd Brake Blue/White 2.701 (68.60)
    Forward Clutch Blue/Green 2.803 (71.20)
    A-540H
    Direct Clutch Red 2.008 (51.00)
    2nd Brake Blue/White 2.701 (68.60)
    Forward Clutch Pink 2.433 (61.80)
    A-541E
    Direct Clutch Yellow/Purple 2.039 (51.08)
    2nd Brake
    1997 Brown/Pink 3.035 (77.10)
    1998
    Inner None 3.472 (88.20)
    Outer None 2.768 (70.30)
    Forward Clutch None 2.898 (73.60)
  21. Install 2nd brake apply gasket. Install throttle cable and solenoid wire. Place valve body on transaxle. While holding cam down with hand, slip cable end in slot. Lower valve body into position. DO NOT entangle solenoid wiring. Install valve body bolts. Ensure proper length and location of bolts. See Figure. Finger tighten all bolts. Tighten bolts in crisscross pattern to specification. See TORQUE SPECIFICATIONS .
  22. Install 1st and reverse brake apply tube. Install connector clamp and tube retainer. Connect solenoid connectors. Using a plastic hammer, install oil tubes. DO NOT bend or damage tubes. Place manual valve body on transmission. Align manual lever with pin of manual shaft lever. Lower manual valve body into position. Ensure proper length and location of bolts. See Figure. Finger tighten bolts. Evenly tighten bolts in crisscross pattern.
  23. Install detent spring. Ensure proper length and location of each bolt. Finger tighten bolts. Check for correct operation of manual valve lever. Ensure lever is touching center of detent spring tip roller.
  24. Install tube bracket and oil strainer. Install magnets in oil pan. Ensure magnets do not interfere with oil tubes. Install oil pan with NEW gasket. Install vehicle speed sensor with "O" ring (as applicable). Install speed sensor connector. Install throttle cable retaining plate. Install solenoid wire.
  25. Install transaxle case upper cover. Install direct clutch speed (T/M revolution) sensor (if equipped). Install park/neutral position switch to manual valve shaft. Install NEW locking plate. Tighten nut and stake with locking plate. Adjust switch by aligning groove and neutral basic line. Tighten bolts. Install manual shift lever.
  26. On A-540H transaxle, install NEW snap ring to shaft groove and install differential side gear intermediate shaft. See Figure. Keeping intermediate shaft on pinion shaft of differential, measure shaft protrusion length from transaxle case surface to end of shaft. Protrusion length should be 10.059" (255.50 mm).
  27. Install NEW apply gasket on differential carrier cover. Install transfer case assembly to transaxle. Apply seal packing Three Bond (1281) or Loctite (518) to contacting surface of transaxle case. Coat threads of bolts with Three Bond (1324) sealer. Install and tighten nuts and bolts to 51 ft. lbs. (69 N.m). Install breather hose to driven pinion bearing cage and transaxle upper cover.
  28. On all transaxles, install cooler line union and elbow. Install elbow at right angles to bottom of case. Install torque converter. Ensure converter is full of ATF before installation. Check installed position by measuring installed depth from edge of case. See Fig 7. Distance should be .539" (13.7 mm).
Fig 7: Measuring Torque Converter Installed Depth
G95J19280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 8: Identifying Thrust Bearing & Race Locations (A-540H)
G96E04910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 9: Identifying Thrust Bearing & Race Locations (A-540E & A-541E)
G95C19531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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