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Transaxle Reassembly

WARNING: This page is about a different variant/trim than selected.
NOTE: Coat all oil seal rings, clutch discs, clutch plates, rotating parts and sliding surfaces with ATF prior to reassembly. All gaskets and rubber "O" rings should be replaced. Ensure ends of snap rings are not aligned with cutouts of drum. Check thrust bearings and races for wear or damage. Use petroleum jelly to secure parts in place. Clutch discs should be soaked in ATF for at least 15 minutes before installation.
NOTE: For thrust bearing and race locations, refer to illustration. See Fig 7. For component dimensions, see THRUST BEARING & RACE SPECIFICATIONS  table.
  1. Install 4 NEW "O" rings and 4 screw plugs to transaxle rear cover. See Figure. Install 3 seal rings to transaxle rear cover. Using vernier calipers, measure O/D brake piston return spring free length with spring mounted to spring seat. Free length should be .704" (17.88 mm). Replace springs as necessary.
  2. Coat 2 NEW "O" rings with ATF and install onto O/D brake piston. Coat O/D brake piston with ATF and install onto transaxle rear cover. Use care not to damage "O" rings.
    3. CAUTION: In the following step, do not compress piston return spring more than .079" (2.00 mm) past snap ring groove. This prevents piston from becoming deformed. DO NOT expand snap ring excessively.
  3. Using appropriate adapter and press, compress O/D brake piston return springs and install snap ring to transaxle rear cover. DO NOT apply excessive force. Using appropriate adapter and a hammer, install roller bearing into transaxle case. Install NEW oil seals into transaxle case and transaxle housing (if necessary). See REASSEMBLY  under DIFFERENTIAL ASSEMBLY.
  4. Using appropriate adapter and a hammer, install thrust needle roller bearing and NEW cylindrical roller bearing. See Figure. Install differential gear apply tube, bearing lock plate and bolt to transaxle housing. See Figure. Tighten bolt to 97 INCH lbs. (11 N.m).
  5. Install transaxle housing oil separator and 2 bolts. See Figure. Tighten bolts to 87 INCH lbs. (9.8 N.m). Coat 2 NEW "O" rings with ATF and install onto 1st/reverse brake piston. Install 1st/reverse brake piston into transaxle case. Use care not to damage "O" rings.
  6. Using vernier calipers, measure 1st/reverse brake piston return spring free length with spring mounted to spring seat. Free length should be .550" (13.96 mm). Replace springs as necessary. Using appropriate adapter, press and a screwdriver, install piston return spring and snap ring into transaxle case.
  7. Install 1st/reverse brake. Install 4 plates and 4 discs, starting with a plate and alternating with a disc. Install flange. Using a screwdriver, install snap ring. Measure 1st/reverse brake clutch pack clearance. Using vernier calipers, measure dimension "A" while by applying and releasing 57 psi (4 kg/cm2 ) of compressed air to transaxle case. See Fig 1. Clutch pack clearance equals dimension "A", minus flange thickness, minus snap ring thickness.
  8. Clutch pack clearance should be .032-.048" (.81-1.21 mm). Select appropriate flange to ensure clutch pack clearance is within specification. Flanges are marked in numeric order and are available in thicknesses from .134" (3.40 mm), marked with the number "1", to .157" (4.00 mm), marked with the number "4", in increments of .008" (.20 mm). Remove snap ring, install appropriate flange and reinstall snap ring. Recheck clutch pack clearance after flange is installed.
  9. Using appropriate adapter and press, install front tapered roller bearing to counter drive gear until bearing contacts gear. DO NOT apply excessive force. Install counter drive gear and bearing into transaxle case. See Figure.
  10. On U341E transaxle, using appropriate adapter and press, install tapered roller bearing onto counter drive gear and transaxle case. DO NOT apply excessive pressure. On both transaxles, using appropriate adapter and press, install front planetary gear to counter drive gear. See Figure.
  11. Using holding tool, socket and torque wrench, install NEW lock washer and nut onto counter drive gear. Tighten nut to 207 ft. lbs. (280 N.m). See Figure. Using socket, adapter and INCH-lb. torque wrench, measure counter drive gear tapered roller bearing rotating torque by rotating counter drive gear 60 turns per minute. Rotating torque should be 2.0-4.0 INCH lbs. (.2-.5 N.m). If rotating torque is not within specification, gradually tighten nut until rotating torque is within specification. Stake lock washer to nut. See Figure.
  12. Install thrust needle bearing and front planetary sun gear. See Figure. Install retainer to No. 2 one-way clutch. See Figure. Assemble 2nd brake cylinder, No. 2 one-way clutch and rear planetary gear. Install thrust needle roller bearing and 2 bearing races to transaxle case. Install 2nd brake cylinder, No. 2 one-way clutch and rear planetary gear into transaxle case. Install snap ring.
  13. Install 2nd brake. Install 2nd brake piston sleeve. On U340E transaxle, install 3 discs and 4 plates, starting with a plate and alternating with a disc. On U341E transaxle, install flange, 4 discs and 3 plates, starting with a flange, then a disc, then a plate and alternating with a disc. Install second flange. Using a screwdriver, temporarily install snap ring.
  14. Using vernier calipers, measure 2nd brake pack clearance dimension "A" while applying pressure to top plate (U340E) or flange (U341E). See Fig 2. Pack clearance equals dimension "A", minus flange thickness, minus snap ring thickness.
  15. Pack clearance should be .033-.049" (.85-1.25 mm). Select appropriate flange to ensure pack clearance is within specification. Flanges are marked in numeric order and are available in thicknesses from .118" (3.00 mm), marked with the number "1", to .142" (3.60 mm), marked with the number "4", in increments of .008" (.20 mm). Remove snap ring, install appropriate flange and reinstall snap ring. Recheck pack clearance after flange is installed.
    Fig 1: Checking 1st/Reverse Brake Clearance
    G00045612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 2: Checking 2nd Brake Pack Clearance
    G00045613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. Install thrust washer No. 2 to rear planetary sun gear. Assemble rear planetary sun gear and No. 1 one-way clutch. Install thrust washer No. 1 and thrust needle roller bearing to No. 1 one-way clutch. Install components into transaxle case. See Figure.
  17. Install thrust needle roller bearing, direct clutch hub, bearing race and thrust needle roller bearing. Install bearing race to direct and reverse clutch multiple disc clutch assembly. Install direct and reverse clutch multiple disc clutch assembly and bearing race to transaxle case.
  18. Using a screwdriver, install 2nd coast and O/D brake snap ring into transaxle case. Install 2 discs and 3 plates, starting with a plate and alternating with a disc. Using vernier calipers, measure 2nd coast and O/D brake pack clearance dimensions "A" and "B" while applying pressure to top plate. See Fig 3. Pack clearance equals dimension "A", minus dimension "B", minus selected flange thickness.
  19. Pack clearance should be .082-.098" (2.09-2.49 mm). Select appropriate flange to ensure pack clearance is within specification. Flanges are marked in numeric order and are available in thicknesses from .157" (4.00 mm), marked with the number "4", to .181" (4.60 mm), marked with the number "7", in increments of .008" (.20 mm). Remove snap ring, install appropriate flange and reinstall snap ring. Recheck pack clearance after flange is installed.
    Fig 3: Checking 2nd Coast & O/D Brake Clearance
    G00045614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. Install thrust needle roller bearing to direct and reverse multiple disc clutch assembly. Install 4 NEW apply gaskets to transaxle case. See Figure. Ensure transaxle case and rear cover surfaces are clean. DO NOT allow oil to contact surfaces. Apply Three Bond (1281) or equivalent gasket sealer to transaxle rear cover sealing surface. Install transaxle rear cover and 11 bolts. Tighten bolts to 18 ft. lbs. (24 N.m).
  21. Install thrust needle roller bearing, counter driven gear and differential drive pinion into transaxle case. Install parking lock pawl, torsion spring and shaft to transaxle case. Install forward clutch hub and thrust needle roller bearing. See Figure.
  22. Install thrust needle roller bearing to forward multiple disc clutch assembly. Install forward multiple disc clutch assembly into transaxle case. Coat oil pump "O" ring with ATF. Install oil pump and 7 bolts. Tighten bolts to 16 ft. lbs. (22 N.m).
  23. Inspect input shaft end play. Using a dial indicator, measure input shaft end play. See Figure. End play should be .015-.051" (.37-1.29 mm). If end play is not as specified, select appropriate thrust needle roller bearing. Install differential assembly into transaxle case.
  24. Install brake drum gasket. See Figure. Install 2 NEW apply gaskets. See Figure. Ensure transaxle case and transaxle housing surfaces are clean. DO NOT allow oil to contact surfaces. Apply Three Bond (1281) or equivalent gasket sealant about .047" (1.20 mm) wide, to transaxle case around inside edges of bolt holes. Install transaxle housing to transaxle case.
  25. Install 14 transaxle housing bolts. Tighten all bolts except 3 lower bolts ("A") inside transaxle housing to 22 ft. lbs. (29 N.m). Tighten 3 lower bolts ("A") inside transaxle housing to 16 ft. lbs. (22 N.m). Ensure bolts are in correct locations. See Figure.
  26. Coat NEW manual valve lever shaft oil seal with ATF. Install oil seal into transaxle case. Install parking lock pawl rod to manual valve lever (if removed). Install NEW spacer to manual valve lever shaft. Install manual valve lever shaft and manual valve lever. Using a pin punch and hammer, drive in NEW pin.
  27. Turn spacer and lever shaft to align small hole for locating staking position in spacer with position mark on lever shaft. Using a pin punch and hammer, stake spacer through small hole. Ensure spacer does not turn. See Fig 4. Using needle nose pliers, install retainer spring. Install cam guide, bracket and 3 bolts. Tighten bolts to 15 ft. lbs. (20 N.m).
    Fig 4: Staking Spacer To Manual Valve Lever Shaft
    G00045615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. Coat NEW "O" rings with ATF and install them onto accumulator pistons. Coat springs and 3 accumulator pistons with ATF, and install components into transaxle case holes. See Figure. See ACCUMULATOR SPRING FREE LENGTH SPECIFICATIONS  table for spring specifications and identification.
    ACCUMULATOR SPRING FREE LENGTH SPECIFICATIONS

    Application (Color) Free Length - In. (mm) Outer Diameter - In. (mm)
    Direct Clutch (C2), (None) 2.634 (66.90) .677 (17.20)
    Reverse Clutch (C3)
    U340E (Blue) 3.158 (80.20) .736 (18.70)
    U341E (Orange) 3.437 (87.30) .736 (18.70)
    2nd Brake (B2)
    U340E (Green) 2.634 (66.90) .610 (15.50)
    U341E (White) 2.634 (66.90) .610 (15.50)
  29. Install check ball body and spring. See Figure. Coat NEW "O" ring with ATF and install on transaxle solenoid connector. Install connector into transaxle case, above park/neutral position switch, and tighten bolt to 48 INCH lbs. (5.4 N.m).
  30. Install valve body assembly. Install magnets in oil pan in original locations. Align groove in manual valve with pin in manual valve lever. Push valve body assembly against check ball body to assist in installation. Install valve body bolts. Ensure manual valve lever contacts center of roller at tip of detent spring.
  31. Ensure valve body is aligned. Ensure bolts are installed in correct locations. For bolt length, see VALVE BODY BOLT IDENTIFICATION  table. Tighten bolts to 97 INCH lbs. (11 N.m). Install NEW "O" ring on oil strainer. Tighten bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.
    VALVE BODY BOLT IDENTIFICATION

    Bolt Identification Length - In. (mm)
    A .87 (22)
    B 1.26 (32)
    C 1.77 (45)
    D 2.17 (55)
    E .55 (14)
  32. Connect 5 shift solenoid connectors. Coat NEW "O" with ATF and install on fluid temperature sensor. Install fluid temperature sensor, lock plate and bolt. Tighten bolt to 97 INCH lbs. (11 N.m). See Figure. Install 2 magnets into oil pan in original locations. Apply Three Bond (2430) or equivalent to 19 oil pan bolt threads. Install NEW oil pan gasket, oil pan and bolts. Tighten bolts to 69 INCH lbs. (7.8 N.m) within 10 minutes of installation.
  33. Coat 4 NEW "O" rings with ATF and install on screw plugs. Install screw plugs and tighten to 65 INCH lbs. (7.4 N.m). Install NEW "O" rings on oil line union and elbow. Install oil line union and elbow into transaxle case. Tighten to 20 ft. lbs. (27 N.m). See Figure.
  34. Coat NEW "O" ring with ATF and install on line pressure test plug. Install transaxle line pressure test plug into transaxle case and tighten to 65 INCH lbs. (7.4 N.m). Install park/neutral position switch onto manual valve lever shaft and temporarily install 2 adjusting bolts. See Figure.
  35. Install NEW lock washer and nut. Tighten nut to 61 INCH lbs. (6.9 N.m). Temporarily install control lever. Turn lever counterclockwise until it stops, then turn it clockwise 2 notches. Remove control lever. Align groove in park/neutral position switch to neutral basic line. Tighten 2 adjusting bolts to 48 INCH lbs. (5.4 N.m). Stake lock washer onto nut. Install control lever, washer and nut. See Figure. Tighten nut to 10 ft. lbs. (14 N.m).
  36. Coat NEW "O" ring with ATF and install on breather plug. Install breather plug, clip and breather hose. Coat NEW "O" ring with ATF and install on transaxle revolution sensor. Install transaxle revolution sensor and bolt. See Figure. Tighten bolt to 48 INCH lbs. (5.4 N.m).
  37. Install torque converter into transaxle housing while rotating. Ensure converter is properly installed by measuring distance from edge of transaxle housing. See Fig 6. On U340E transaxle, distance should be .366" (9.30 mm). On U341E transaxle, distance should be .524" (13.30 mm).
    Fig 5: Identifying Valve Body Bolt Locations
    G00015258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 6: Measuring Torque Converter Depth
    G95J19280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 7: Identifying Thrust Bearing & Race Locations
    G00045616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    THRUST BEARING & RACE SPECIFICATIONS (1)

    Application Inner Diameter - In. (mm) Outer Diameter - In. (mm)
    A
    Bearing 1.776 (45.10) 2.563 (65.10)
    B
    Bearing 1.024 (26.00) 1.709 (43.40)
    C
    Bearing .827 (21.00) 1.372 (34.85)
    D
    Bearing 1.260 (32.00) 1.890 (48.00)
    E
    Front Race 1.447 (36.75) 1.967 (49.95)
    Bearing 1.335 (33.90) 2.047 (52.00)
    Rear Race N/A 2.035 (51.70)
    F
    Bearing 1.711 (43.45) 2.303 (58.50)
    G
    Bearing 1.157 (29.40) 1.748 (44.40)
    H
    Front Race .925 (23.50) 1.469 (37.30)
    Bearing .886 (22.50) 1.469 (37.30)
    Rear Race .799 (20.30) 1.331 (33.80)
    I
    Bearing 1.711 (43.45) 2.410 (61.20) Or 2.431 (61.74)
    (1) For component locations, refer to illustration. See Fig 7.
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