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Automatic Transaxle Unit: Reassembly

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  1. BEARING POSITION 
    Fig 1: Bearing Position Assembly Chart
    G04487184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Standard bearing position 

    STANDARD BEARING POSITION

    Mark Front Race Diameter Inside / Outside Thrust Bearing Diameter Inside / Outside Rear Race Diameter Inside / Outside
    A - 57.2 mm (2.252 in.) / 84.96 mm (3.3449 in.) 56.4 mm (2.220 in.) / 83.0 mm (3.268 in.)
    B - 37.73 mm (1.4854 in.) / 58.0 mm (2.283 in.) -
    C - 33.85 mm (1.3327 in.) / 52.2 mm (2.055 in.) -
    D 24.94 mm (0.982 in.) 23.5 mm (0.925 in.) / 44.0mm (1.732 in.) -
    E - 36.3 mm (1.429 in.) / 51.93 mm (2.0445 in.) 34.5 mm (1.358 in.) / 48.35 mm (1.904 in.)
    F 34.35 mm (1.3524 in.) / 56.57 mm (2.2272 in.) 32.45 mm (1.2776 in.) / 56.48 mm (2.2236 in.) -
    G 40.15 mm (1.5807 in.) / 59.25 mm (2.3327 in.) 38.65 mm (1.5217 in.) / 59.79 mm (2.3539 in.) 38.65 mm (1.5217 in.) / 59.25 mm (2.3327 in.)
    H - 53.6 mm (2.110 in.) / 69.6 mm (2.740 in.) -
    I 33.02 mm (1.3000 in.) / 45.8 mm (1.803 in.) 31.85 mm (1.2539 in.) / 57.3 mm (2.256 in.) -
    J - 24.79 mm (0.9760 in.) / 39.5 mm (1.555 in.) 23.6 mm (0.929 in.) / 37.95 mm (1.4941 in.)
    K - 56.3 mm (2.216 in.) / 75.96 mm (2.9905 in.) -
  2. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE 
    1. Install the differential gear lube apply tube and transaxle apply tube clamp to the transaxle housing with the bolt.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

      NOTE: Make sure to insert the pipe to the stopper.
      Fig 2: Installing Differential Gear Lube Apply Tube
      G04487185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 1 TRANSAXLE CASE PLUG 
    1. Install 2 new O-rings to the 2 plugs.
    2. Install the 2 plugs to the transaxle rear cover.

      Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

      Fig 3: Installing No. 1 Transaxle Case Plug
      G04487186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING 
    1. Coat a new oil seal ring with ATF and install it to the transaxle housing.
      Fig 4: Installing Underdrive Output Shaft Oil Seal Ring
      G04487187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING 
    1. Coat the underdrive cylindrical roller bearing with ATF.
    2. Using SST and a press, press in the underdrive cylindrical roller bearing.

      SST 09950-60020 (09951-00810), 09950-70010 (09951-07100) 

      NOTE: Do not apply excessive pressure to the bearing.
      Fig 5: Pressing In Underdrive Cylindrical Roller Bearing
      G04487827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING 
    1. Coat 2 new oil seal rings with ATF, and install them to the transaxle rear cover.
      NOTE:
      • Do not expand the end gap of the oil seal ring too much.
      • Fix the hooks firmly. Confirm that the oil seal ring rotates freely in its groove.
        Fig 6: Installing Underdrive Clutch Drum Oil Seal Ring
        G04487189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL NEEDLE ROLLER BEARING 
    1. Wrap vinyl tape around SST 4.0 mm (0.157 in.) from the bottom of SST until the thickness of the tape is about 5.0 mm (0.197 in.).

      SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) 

      NOTE: Clean SST to remove deposited oil before wrapping vinyl tape.
    2. Coat the needle roller bearing with ATF.
      Fig 7: Wraping Vinyl Tape Around SST
      G04487190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, press in the needle-roller bearing to the transaxle case.

      SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) 

      NOTE: When the wrapped vinyl tape contacts the transaxle case, stop press-fitting.
      Fig 8: Pressing In Needle-Roller Bearing To Transaxle Case
      G04487191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL UNDERDRIVE BRAKE PISTON 
    1. Coat 2 new O-rings with ATF, and install them to the underdrive brake piston.
      NOTE:
      • Make sure that the O-rings are not twisted or pinched when they are installed.
      • Apply sufficient ATF to the O-ring before installing.
    2. Coat the underdrive brake piston with ATF.
      Fig 9: Installing O-Rings To Underdrive Brake Piston
      G04487192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the underdrive brake piston to the transaxle case.
      NOTE: Be careful not to damage the O-ring.
      Fig 10: Installing Underdrive Brake Piston To Transaxle Case
      G04487193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the return spring and compress the return spring with a press.
      NOTE:
      • Stop the press when the spring seat is lowered to a position 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from being deformed.
      • After installing the return spring, check that all the return spring's springs fit in the piston correctly.

      SST 09387-00020 

      Fig 11: Installing Underdrive Brake Return Spring Sub-Assembly
      G04487194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, press in the snap ring to the transaxle case.
      NOTE: The snap ring must be fully engaged in the groove of the transaxle case.
  10. INSTALL NO. 2 BREATHER PLUG 
  11. INSTALL COUNTER DRIVE GEAR BEARING 
    1. Coat the counter drive gear bearing with ATF.
    2. Using SST and a press, press in the bearing outer race.

      SST 09950-60020 (09951-01030), 09950-70010 (09951-07150), 09649-17010 

      NOTE:
      • Do not apply excessive pressure to the bearing.
      • Press-fit the bearing outer race until it contacts the transaxle case.
        Fig 12: Pressing In Bearing Outer Race
        G04487195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a snap ring expander, install the snap ring.
      NOTE: The white mark side of the snap ring should face upward.
      Fig 13: Installing Snap Ring
      G04487196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL COUNTER DRIVE GEAR 
    1. Coat the counter drive gear with ATF.
    2. Using SST and a press, press in the tapered roller bearing to the counter drive gear.

      SST 09950-70010 (09951-07150), 09649-17010 

      NOTE: Do not apply excessive pressure to the bearing.
      Fig 14: Pressing In Tapered Roller Bearing To Counter Drive Gear
      G04487197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, press in the counter drive gear and bearing to the transaxle case.

      SST 09950-70010 (09951-07150), 09223-15030, 09527-17011, 09950-60020 (09951-00750) 

      NOTE: Do not apply excessive pressure to the counter drive gear.
      Fig 15: Pressing In Counter Drive Gear And Bearing To Transaxle Case
      G04487198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL 1ST AND REVERSE BRAKE PISTON 
    1. Coat 2 new O-rings with ATF.
    2. Install the 2 O-rings to the 1st and reverse brake piston.
      NOTE:
      • Make sure that the O-rings are not twisted or pinched when they are installed.
      • Apply sufficient ATF to the O-ring prior to assembling.
        Fig 16: Installing O-Rings To 1st And Reverse Brake Piston
        G04487199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the 1st and reverse brake piston with ATF, and install it to the transaxle case.
      NOTE: Be careful not to damage the O-ring.
      Fig 17: Installing 1st And Reverse Brake Piston To Transaxle Case
      G04487200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the return spring and compress the return spring with a press.
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from being deformed.
      • After installing the return spring, check that all the return spring's springs fit in the piston correctly.

      SST 09387-00070 

      Fig 18: Compressing Return Spring Using SST
      G04425413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, press in the snap ring to the transaxle case.
      NOTE:
      • The snap ring must be fully engaged in the groove of the transaxle case.
      • Fix the snap ring to the inside of the claw of the spring seat firmly.
  15. INSTALL FRONT PLANETARY RING GEAR 
    1. Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.
      NOTE: Confirm that the snap ring is engaged in the groove of the brake hub correctly.
      Fig 19: Installing Front Planetary Ring Gear And Snap Ring To Brake Hub
      G04487202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FRONT PLANETARY GEAR ASSEMBLY 
    1. Install the front planetary gear to the brake hub.
      Fig 20: Installing Front Planetary Gear To Brake Hub
      G04487203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, press-fit the front planetary gear.

      SST 09950-60010 (09951-00500), 09950-70010 (09951-07100) 

      NOTE:
      • Do not apply excessive pressure to the planetary gear.
      • Press the inner race of the LH tapered roller bearing, counter gear and front planetary gear to the position where no preload should be applied to one pair of tapered roller bearings (left and right).
        Fig 21: Pressing Front Planetary Gear
        G04487204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new washer as shown in the illustration.
      Fig 22: Installing Front Planetary Gear Washer
      G04487205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, install the nut.

      SST 09387-00030, 09387-00080 

      Torque: 280 N*m (3,355 kgf*cm, 207 ft.*lbf) 

      NOTE: Assemble the washer after pressing each part, then tighten the nut to the standard torque.
      Fig 23: Installing Front Planetary Gear Nut
      G04487206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm. When the measured value is not as specified, gradually tighten the nut until it reaches the specified value.

      SST 09387-00080 

      Standard turning torque at 60 rpm: 

      0.51 to 1.02 N*m (5.1 to 10.0 kgf*cm, 4.4 to 8.7 in.*lbf) for new bearing 

      0.26 to 0.51 N*m (2.7 to 5.2 kgf*cm, 2.3 to 4.5 in.*lbf) for used bearing 

      Fig 24: Measuring Turning Torque Of Bearing While Rotating SST At 60 rpm
      G04487207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Tighten the nut gradually until the specified turning torque of the tapered roller bearing is measured.

      Torque: 350 N*m (3,569 kgf*cm, 258 ft.*lbf) 

    7. Using a chisel and hammer, stake the front lock washer.
      Fig 25: Staking Front Lock Washer
      G04487208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL INPUT SUN GEAR 
    1. Coat the 2 thrust bearings with ATF.
    2. Install the 2 thrust bearings, bearing race and input sun gear to the front planetary gear.
      NOTE:
      • Install the bearing race on the side of the front planetary carrier. Be careful about the direction of the race.
      • When installing the thrust bearing and front sun gears, be careful about the direction of the parts.
      • When install the bearing race on the side of the front sun gear, be careful of the direction of the race.
      • Install the thrust bearing and the race after holding the parts on the input sun gear by applying grease. Make sure that the assembling order is correct.
        Fig 26: Installing Thrust Bearings, Bearing Race And Input Sun Gear To Front Planetary Gear
        G04487209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard thrust bearing and bearing race diameter 

      STANDARD THRUST BEARING AND BEARING RACE DIAMETER

      Item Inside Outside
      Thrust Bearing, A 32.5 mm (1.28 in.) 56.5 mm (2.224 in.)
      Thrust Bearing, C 38.6 mm (1.520 in.) 59.7 mm (2.35 in.)
      Bearing Race, B 40.2 mm (1.583 in.) 59.3 mm (2.335 in.)
      Bearing Race, D 38.6 mm (1.520 in.) 59.3 mm (2.335 in.)
  18. INSTALL REAR PLANETARY GEAR ASSEMBLY 
    1. Install the rear planetary gear to the rear planetary ring gear.
      Fig 27: Installing Rear Planetary Gear To Rear Planetary Ring Gear
      G04487210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, install the snap ring.
      NOTE: Confirm that the snap ring is fixed in the groove of the 1st and reverse brake hub correctly.
      Fig 28: Installing Snap Ring
      G04487211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC 
    1. Coat the 6 discs with the ATF.
    2. Install the 6 plates and 6 discs.
      NOTE: Make sure that the plates and discs are installed as shown in the illustration.
      Fig 29: Installing 1st And Reverse Brake Clutch Disc
      G04487212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE 
    1. Using a vernier caliper, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case (Dimension A).
    2. Select an appropriate flange so that the pack clearance will meet the specified value.

      Standard pack clearance: 1.16 to 1.35 mm (0.0457 to 0.0531 in.) 

      HINT:

      Piston stroke = Dimension A - Flange thickness

      Fig 30: Measuring (Dimension A)
      G04377687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard flange thickness 

      STANDARD FLANGE THICKNESS

      Mark Thickness Mark Thickness
      1 1.8 mm (0.071 in.) 5 2.2 mm (0.087 in.)
      2 1.9 mm (0.075 in.) 6 2.3 mm (0.091 in.)
      3 2.0 mm (0.079 in.) 7 2.4 mm (0.094 in.)
      4 2.1 mm (0.083 in.) 8 2.5 mm (0.098 in.)
    3. Install the flange.
      Fig 31: Installing Flange
      G04487214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL SECOND BRAKE PISTON ASSEMBLY 
    1. Install the second brake piston to the transaxle case.
      Fig 32: Installing Second Brake Piston To Transaxle Case
      G04487215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the snap ring and measure the inside diameter.

    Inside diameter: Greater than 167 mm (6.57 in.) 

    NOTE:
    • Make sure that the taper snap ring is installed in the correct direction.
    • When the diameter does not meet the specified value, replace the snap ring with a new one.
    • After installing the snap ring, confirm that there is no clearance between the 2nd brake cylinder and the fitting surface of the cylinder in the transaxle case.
      Fig 33: Installing Snap Ring And Measure Inside Diameter
      G04487216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL 1-WAY CLUTCH SLEEVE OUTER 
    1. Install the 1-way clutch sleeve outer to the 2nd brake cylinder.
      NOTE: Make sure that the outer sleeve is installed in the correct direction.
      Fig 34: Installing 1-Way Clutch Sleeve Outer To 2nd Brake Cylinder
      G04487217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL 1-WAY CLUTCH ASSEMBLY 
    1. Install the 1-way clutch inner race to the 1-way clutch.
      NOTE:
      • Make sure that the inner race is installed in the correct direction.
      • Confirm that the discrimination mark is visible.
        Fig 35: Installing 1-Way Clutch Inner Race To 1-Way Clutch
        G04487218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check that the 1-way clutch locks when turned clockwise and rotates freely when turned counterclockwise as shown in the illustration. If the result is not as specified, replace the 1-way clutch.
      Fig 36: Checking 1-Way Clutch Locks When Turned Clockwise And Rotates Freely When Turned Counterclockwise
      G04487219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 1-way clutch and thrust needle roller bearing to the 1-way clutch sleeve outer.

      Standard bearing diameter 

      STANDARD BEARING DIAMETER

      Item Inside Outside
      Bearing 53.6 mm (2.110 in.) 69.4 mm (2.732 in.)
      NOTE: Install the thrust bearing properly so that the non-colored race will be visible.
      Fig 37: Installing 1-Way Clutch And Thrust Needle Roller Bearing To 1-Way Clutch Sleeve Outer
      G04487220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL NO. 1 PLANETARY CARRIER THRUST WASHER 
    1. Coat the planetary carrier thrust washer with yellow petrolatum, and install the washer onto the planetary sun gear.
      NOTE: After installing the washer, confirm that the projection of the washer is fixed firmly in the hole of the planetary sun gear.
      Fig 38: Installing Washer Onto Planetary Sun Gear
      G04487221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY 
    1. Coat the planetary carrier thrust washer with yellow petrolatum, and install the washer onto the rear planetary sun gear.
      Fig 39: Installing Washer Onto Rear Planetary Sun Gear
      G04487222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the bearing with yellow petrolatum, and install the bearing onto the rear planetary sun gear.

      Standard bearing diameter 

      STANDARD BEARING DIAMETER

      Item Inside Outside
      Race 33.0 mm (1.299 in.) 45.4 mm (1.787 in.)
      Bearing 31.85 mm (1.254 in.) 45.2 mm (1.78 in.)
      Fig 40: Installing Bearing Onto Rear Planetary Sun Gear
      G04487223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the rear planetary sun gear to the rear planetary gear.
      NOTE: After installing the rear planetary sun gear, make sure that the B1 discs are engaged.
      Fig 41: Installing Rear Planetary Sun Gear To Rear Planetary Gear
      G04487224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL 2ND BRAKE CLUTCH DISC 
    1. Coat the 4 discs with ATF.
    2. Install the 4 plates and 4 discs to the transaxle case.
      NOTE: Make sure that the plates and discs are installed as shown in the illustration.
    3. Temporarily install the snap ring.
      Fig 42: Installing 2nd Brake Clutch Disc
      G04487225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSPECT PACK CLEARANCE OF 2ND BRAKE 
    1. Using a vernier caliper, measure the distance between the disc surface and snap ring surface (Dimension B).
    2. Select an appropriate flange so that the pack clearance will meet the specified value.

      Standard clearance: 0.62 to 0.91 mm (0.0244 to 0.0358 in.) 

      Fig 43: Measuring Dimension B
      G04377734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Piston stroke = Dimension B - Flange thickness - Snap ring thickness 1.6 mm (0.063 in.)

      Standard flange thickness 

      STANDARD FLANGE THICKNESS

      Mark Thickness Mark Thickness
      1 3.0 mm (0.118 in.) 5 3.4 mm (0.134 in.)
      2 3.1 mm (0.122 in.) 6 3.5 mm (0.138 in.)
      3 3.2 mm (0.126 in.) 7 3.6 mm (0.142 in.)
      4 3.3 mm (0.130 in.) 8 -
    3. Temporarily remove the snap ring, attach the selected flange and reinstall the snap ring.
      NOTE: Secure the snap ring so that the ends are visible through the groove of the transaxle case.
      Fig 44: Installing Snap Ring
      G04487227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL OVERDRIVE DIRECT CLUTCH HUB SUBASSEMBLY 
    1. Install the direct clutch hub to the planetary gear.
      NOTE: Be careful not to damage the bushing inside the overdrive clutch hub during installation.
    2. Coat the thrust bearing with ATF.
    3. Install the bearing race and the thrust bearing to the direct clutch hub.
      NOTE: Be careful not to drop the bearing when it is installed.
      Fig 45: Installing Overdrive Direct Clutch Hub Subassembly
      G04487228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard bearing and race diameter 

      STANDARD BEARING AND RACE DIAMETER

      Item Inside Outside
      Bearing 24.7 mm (0.972 in.) 39.5 mm (1.555 in.)
      Race 23.6 mm (0.929 in.) 38.0 mm (1.496 in.)
  29. INSTALL DIRECT CLUTCH ASSEMBLY 
    1. Coat the thrust bearing with ATF.
    2. Install the direct clutch and thrust bearing to the rear planetary sun gear.
      NOTE: The disc in the direct clutch should completely match with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed.
      Fig 46: Installing Direct Clutch And Thrust Bearing To Rear Planetary Sun Gear
      G04487229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Clean the connecting part of the transaxle case and the rear cover.
    4. As shown in the illustration, place a straightedge on the direct clutch drum and measure the distance between the transaxle case and the straightedge using a vernier caliper (Dimension C).
      Fig 47: Measuring Distance Between Transaxle Case And Straightedge
      G04487230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a vernier caliper and straightedge, measure the dimension shown in the illustration (Dimension D).
    6. Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install the selected bearing.

      Standard end play: 0.244 to 0.901 mm (0.0096 to 0.0355 in.) 

      NOTE: Make sure that the non-collared race side is facing the direct clutch.

      HINT:

      End play = Dimension D - Dimension C

      Fig 48: Measuring Dimension D
      G04487231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard bearing thickness and diameter 

      STANDARD BEARING THICKNESS AND DIAMETER

      Thickness Inside Outside
      3.6 mm (0.1417 in.) 56.3 mm (2.217 in.) 75.7 mm (2.980 in.)
      3.8 mm (0.1496 in.) 56.3 mm (2.217 in.) 75.7 mm (2.980 in.)
  30. INSTALL NO. 1 GOVERNOR APPLY GASKET 
    1. Install 3 new governor apply gaskets to the transaxle case.
  31. INSTALL BRAKE APPLY TUBE 
    1. Install the clamp to the brake apply tube.
      NOTE: Make sure to install the clamp to the apply tube before installing the apply tube to the transaxle case. This prevents the apply tube from being deformed or damaged.
    2. Install the clutch apply tube.
      Fig 49: Installing Governor Apply Gaskets To Transaxle Case
      G04487232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the brake apply tube to the transaxle case with the bolt.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      NOTE: The tube should be securely inserted until it reaches the stopper.
      Fig 50: Installing Brake Apply Tube To Transaxle Case With Bolt
      G04487233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL NEEDLE ROLLER BEARING 
    1. Using SST and a press, press the needle roller bearing into the transaxle rear cover.

      SST 09950-60010 (09951-00230, 09952-06010) 

      Standard depth: 20.55 to 21.25 mm (0.8091 to 0.8366 in.) 

      NOTE:
      • The engraved mark side of the bearing should face upward.
      • Continue pressing until the specified value is obtained.
    2. Coat a needle roller bearing with ATF.
      Fig 51: Installing Needle Roller Bearing
      G04487234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL REAR CLUTCH OIL SEAL RING OUTER 
    1. Coat 3 new rear clutch oil seal rings with ATF, and install them to the transaxle rear cover.
      NOTE: The snap ring should be fully engaged in the groove of the drum.
      Fig 52: Installing Rear Clutch Oil Seal Ring Outer
      G04487235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL NO. 1 TRANSAXLE CASE PLUG 
    1. Coat 4 new O-rings with ATF.
    2. Install the 4 O-rings to the 4 plugs.
    3. Install the 4 plugs to the transaxle rear cover.

      Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

      Fig 53: Installing No. 1 Transaxle Case Plug
      G04487236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY 
    1. Remove any packing material and be careful not to spill oil on the contact surfaces of the transaxle rear cover or the transaxle case.
    2. Apply FIPG to the cover.

      Seal packing: Toyota Genuine Seal Packing 1281, 

      Three Bond 1281 or Equivalent 

      NOTE: Make sure that the seal packing is applied in a bead (section diameter: 1.2 mm (0.047 in.)) so that the entire sealing surface will be evenly sealed. The seal packing should also protrude slightly from the flange after the installation of the cover has been completed.
      Fig 54: Removing Packing Material On Contact Surfaces Of Transaxle Rear Cover Or Transaxle Case
      G04487237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply adhesive to the threads of bolt A.

      Adhesive: Toyota Genuine Adhesive 1344, 

      Three Bond 1344 or Equivalent 

    4. Install the cover with the 11 bolts.

      Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) for bolt A 

      25 N*m (255 kgf*cm, 18 ft.*lbf) for other bolts 

      Fig 55: Applying Adhesive To Threads Of Bolt A
      G04487238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC 
    1. Coat the 4 discs with ATF.
    2. Install the 4 discs, 4 plates and flange to the transaxle case.
      NOTE: Be careful of the order of the discs, plate and flange.
      Fig 56: Installing No. 2 Underdrive Clutch Disc
      G04487239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, install the snap ring.
      NOTE: The snap ring should be fully engaged in the groove of the drum.
      Fig 57: Removing/Installing Snap Ring
      G04377749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE 
    1. Using a dial indicator, measure the underdrive brake pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi).

      Standard pack clearance: 1.81 to 2.20 mm (0.0713 to 0.0866 in.) 

      HINT:

      Select an appropriate flange from the table below so that it will meet the specified value.

      Fig 58: Measuring Underdrive Brake Pack Clearance
      G04487241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard flange thickness 

      STANDARD FLANGE THICKNESS

      Mark Thickness Mark Thickness
      1 3.0 mm (0.118 in.) 4 3.1 mm (0.122 in.)
      2 3.2 mm (0.126 in.) 5 3.3 mm (0.130 in.)
      3 3.4 mm (0.134 in.) - -
    2. Temporarily remove the snap ring, attach the selected flange and reinstall the snap ring.
    3. Reinstall the snap ring.
  38. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY 
    1. Install the underdrive clutch to the 1-way clutch.
    2. Check that the underdrive 1-way clutch locks when turned clockwise and rotates freely when turned counterclockwise as shown in the illustration. If the result is not as specified, replace the underdrive 1-way clutch.
      Fig 59: Checking Underdrive Clutch Assembly Rotation
      G04425501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY 
    1. Install the outer race retainer to the 1-way clutch.
      NOTE: Fix the outer race retainer to the external tooth of the 1-way clutch firmly.
      Fig 60: Installing Outer Race Retainer To 1-Way Clutch
      G04487243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 1-way clutch to the transaxle case.
      NOTE: Make sure that the mark on the 1-way clutch outer race is visible.
      Fig 61: Installing 1-Way Clutch To Transaxle Case
      G04487244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, install the snap ring to the transaxle case.
      NOTE: The snap ring should be fully engaged in the groove of the transaxle case.
      Fig 62: Installing Snap Ring To Transaxle Case
      G04487245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL UNDERDRIVE CLUTCH ASSEMBLY 
    1. Coat the bearing and bearing race with petrolatum, and install them onto the underdrive clutch.

      Standard bearing and bearing race diameter 

      STANDARD BEARING AND BEARING RACE DIAMETER

      Item Inside Outside
      Bearing 37.73 mm (1.4854 in.) 58.0 mm (2.2835 in.)
      Race 29.9 mm (1.1772 in.) 55.5 mm (2.185 in.)
    2. Install the underdrive clutch to the transaxle case.
      NOTE: Do not damage the oil seal when installing the underdrive clutch drum.
      Fig 63: Installing Underdrive Clutch To Transaxle Case
      G04487246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL PARKING LOCK PAWL 
    1. Install the pawl pin and spring to the parking lock pawl.
      Fig 64: Installing Pawl Pin And Spring To Parking Lock Pawl
      G04487247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the parking lock pawl, shaft and spring to the transaxle case, as shown in the illustration.
      Fig 65: Installing Parking Lock Pawl, Shaft And Spring To Transaxle Case
      G04487248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY 
    1. Install the underdrive planetary gear to the transaxle case.
      NOTE:
      • Fully engage all the discs of underdrive clutch and hub splines of the underdrive planetary gear and install them securely.
      • Check the position and number of the grooves on each end face of the differential drive pinion gear.
        Fig 66: Installing Underdrive Planetary Gear To Transaxle Case
        G04487249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the parking lock pawl shaft.
      Fig 67: Installing Parking Lock Pawl Shaft
      G04487250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the pawl shaft clamp with the bolt.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

      Fig 68: Installing Pawl Shaft Clamp With Bolt
      G04487251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a straightedge and vernier caliper as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and the contact surface of the transaxle case and housing (Dimension E).
      NOTE: Record dimension E for the following process.
      Fig 69: Measuring Dimension E
      G04377761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. As shown in the illustration, measure the 2 places of the transaxle housing, and calculate dimension F using the formula below.
      NOTE: Record dimension F for the following process.

      HINT:

      Dimension F = Dimension (1) - Dimension (2)

      Fig 70: Identifying Dimension 1 And 2
      G04377762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL MULTIPLE DISC CLUTCH HUB 
    1. Install the thrust bearing race to the transaxle case while checking its direction.

      Standard bearing race diameter 

      STANDARD BEARING RACE DIAMETER

      Item Inside Outside
      Bearing race 39.5 mm (1.555 in.) 45.8 mm (1.803 in.)
      Fig 71: Installing Thrust Bearing Race To Transaxle Case
      G04487254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the thrust needle roller bearing and race with yellow petrolatum, and install them onto the multiple disc clutch hub.

      Standard thrust bearing and race diameter 

      STANDARD THRUST BEARING AND RACE DIAMETER

      Item Inside Outside
      Thrust Bearing 36.4 mm (1.433 in.) 52.2 mm (2.055 in.)
    3. Coat the needle roller bearing with ATF.
      Fig 72: Installing Needle Roller Bearing
      G04487255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the needle roller bearing to the multiple clutch hub.

      Standard bearing diameter 

      STANDARD BEARING DIAMETER

      Item Inside Outside
      Bearing 23.6 mm (0.929 in.) 44 mm (1.732 in.)
    5. Install the multiple clutch hub to the transaxle case.
      Fig 73: Installing Needle Roller Bearing To Multiple Clutch Hub
      G04487256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL FORWARD CLUTCH ASSEMBLY 
    1. Coat the thrust needle roller bearing with ATF.
    2. Install the thrust needle roller bearing to the forward clutch.

      Standard thrust bearing diameter 

      STANDARD THRUST BEARING DIAMETER

      Item Inside Outside
      Thrust Bearing 33.58 mm (1.3220 in.) 51.9 mm (2.043 in.)
      Fig 74: Installing Thrust Needle Roller Bearing To Forward Clutch
      G04487257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Install the thrust bearing properly so that the non-collared race or blue ink jet race will be visible.
    3. Install the forward clutch to the transaxle case.
      NOTE:
      • Align the splines of all discs in the forward clutch with those of multiple clutch hub to install them securely.
      • Be careful not to damage the bushing inside of the forward clutch hub during installation.
        Fig 75: Installing Forward Clutch To Transaxle Case
        G04487258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL OVERDRIVE BRAKE GASKET 
    1. Install 2 new overdrive brake gaskets.
      Fig 76: Installing Overdrive Brake Gaskets
      G04487259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL DIFFERENTIAL GEAR ASSEMBLY 
    1. Install the differential gear to the transaxle case.
      NOTE: Check the position and number of the grooves on each end face of the differential ring gear.
      Fig 77: Installing Differential Gear To Transaxle Case
      G04487260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE 
    1. Install the thrust bearing underdrive race to the underdrive planetary gear.
      Fig 78: Installing Thrust Bearing Underdrive Race To Underdrive Planetary Gear
      G04487261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL THRUST NEEDLE ROLLER BEARING 
    1. Coat the thrust needle roller bearing with ATF.
    2. Calculate the end play value using the following formula and values of Dimension E and F that were measured when installing the cylindrical roller bearing and underdrive planetary gear. Select an appropriate underdrive planetary gear thrust bearing race which satisfies the specified end play value, and install the selected bearing race.

      Standard end play: 0.498 to 0.993 mm (0.0196 to 0.0391 in.) 

      Fig 79: Installing Thrust Needle Roller Bearing
      G04487262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      End play = Dimension F - Dimension E - thrust bearing thickness 2.5 mm (0.0984 in.) - underdrive thrust bearing race thickness.

      Standard race thickness 

      STANDARD RACE THICKNESS

      F - E Thickness
      Less than 7.72 mm (0.3039 in.) 3.5 mm (0.138 in.)
      7.72 mm (0.3039 in.) 3.8 mm (0.150 in.)

      Standard bearing and bearing race diameter 

      STANDARD BEARING AND BEARING RACE DIAMETER

      Item Inside Outside
      Bearing 57.2 mm (2.252 in.) 84.96 mm (3.345 in.)
      Bearing race 56.4 mm (2.22 in.) 83 mm (3.268 in.)
  49. INSTALL OIL PUMP ASSEMBLY 
    1. Install the oil pump to the transaxle case with the 7 bolts.

      Torque: 22 N*m (226 kgf*cm, 16 ft.*lbf) 

      Fig 80: Identifying Oil Pump To Transaxle Case With Bolts
      G04384533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the O-ring of oil pump with ATF.
      NOTE: Confirm that the input shaft rotates smoothly by manual operation after installing the oil pump.
      Fig 81: Coating O-Ring Of Oil Pump With ATF
      G04487264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL TRANSAXLE HOUSING 
    1. Remove any packing material and be careful not to spill oil on the contact surface of the transaxle case or transaxle housing.
    2. Apply seal packing to the transaxle case.

      Seal packing: Toyota Genuine Seal Packing 1281, 

      Three Bond 1281 or Equivalent 

    3. Apply adhesive or equivalent to bolts A and D.

      Adhesive: 

      Toyota Genuine Adhesive 1344, 

      Three Bond 1344 or Equivalent 

      Fig 82: Applying Seal Packing To Transaxle Case
      G04487265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the transaxle housing and 16 bolts to the transaxle case.

      Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) for bolt A 

      29 N*m (295 kgf*cm, 21 ft.*lbf) for bolt B 

      29 N*m (295 kgf*cm, 21 ft.*lbf) for bolt C 

      22 N*m (226 kgf*cm, 16 ft.*lbf) for bolt D 

      HINT:

      Each bolt length is indicated below.

      Bolt length: 

      50 mm (1.97 in.) for bolt A 

      50 mm (1.97 in.) for bolt B 

      42 mm (1.65 in.) for bolt C 

      72 mm (2.84 in.) for bolt D 

      Fig 83: Installing Transaxle Housing Bolts
      G04487266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Tighten the bolts within 10 minutes of adhesive application.
  51. INSPECT INPUT SHAFT END PLAY 
    1. Using a dial indicator, measure the input shaft end play.

      Standard end play: 0.262 to 1.249 mm (0.0100 to 0.0494 in.) 

      Fig 84: Measuring Input Shaft End Play
      G04487267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. FIX AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Fix the transaxle.
      Fig 85: Fixing Automatic Transaxle Assembly
      G04487268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL 
    1. Coat a new oil seal with MP grease.
    2. Install the oil seal to the transaxle case.

      SST 09950-60010 (09951-00230), 09950-70010 (09951-07100) 

      Standard depth: 0 +-0.5 mm (0 +-0.197 in. ) 

      Fig 86: Installing Manual Valve Lever Shaft Oil Seal
      G04487269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. INSTALL PARKING LOCK ROD SUB-ASSEMBLY 
    1. Install the parking lock rod to the manual valve lever.
      Fig 87: Installing Parking Lock Rod To Manual Valve Lever
      G04487270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY 
    1. Install a new spacer and manual valve lever shaft to the transaxle case.
      NOTE: Do not damage the oil seal when installing the shaft to the transaxle case.
      Fig 88: Installing Spacer And Manual Valve Lever Shaft To Transaxle Case
      G04487271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch and hammer, drive in a new pin.
      Fig 89: Driving In Pin
      G04487272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the spacer and the lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.
    4. Using a pin punch, stake the spacer through the small hole.
    5. Check that the spacer does not turn.
      Fig 90: Staking Spacer Through Small Hole
      G04487273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING 
    1. Using needle-nose pliers, install the retainer spring.
      NOTE: Hang the spring on the shaft firmly.
      Fig 91: Installing Manual Valve Lever Shaft Retainer Spring
      G04487274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL PARKING LOCK PAWL BRACKET 
    1. Install the parking lock pawl bracket with the 2 bolts.

      Torque: 20 N*m (205 kgf*cm, 15 ft.*lbf) 

      HINT:

      The bolt length is indicated below.

      Bolt length: 25.0 mm (0.984 in.) 

      NOTE: Make sure that the parking rod is placed between the parking pawl and the guide of the parking bracket when the parking bracket is installed.
      Fig 92: Installing Parking Lock Pawl Bracket With Bolts
      G04487275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY 
    1. Install the manual detent spring and cover with the 2 bolts.

      Torque: 20 N*m (205 kgf*cm, 15 ft.*lbf) for bolt A 

      12 N*m (122 kgf*cm, 9 ft.*lbf) for bolt B 

      HINT:

      • Tighten bolt A first, and then bolt B.
      • Each bolt length is indicated below.

        Bolt length: 27 mm (1.06 in.) for bolt A 

        16 mm (0.63 in.) for bolt B 

        NOTE: Make sure to install the manual detent spring and cover in this order.
        Fig 93: Identifying Manual Detent Spring
        G04486643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. INSTALL B-3 ACCUMULATOR PISTON 
    1. Coat a new O-ring with ATF, and install it to the B-3 accumulator piston.
      NOTE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position.
      Fig 94: Installing O-Ring To B-3 Accumulator Piston
      G04487277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the accumulator piston to the transaxle case.
      1. Coat the piston with ATF.
      2. Install the 2 springs to the piston, and install the piston (with springs) to the transaxle case.
        NOTE: Before installing the springs, check the identification color of each spring. Standard accumulator spring

        Standard accumulator spring 

        STANDARD ACCUMULATOR SPRING

        Spring Free length / Outer diameter Identification Color
        Inner Inner 62.00 mm (2.4409 in.) / 15.50 mm (0.610 in.) Purple
        Outer Outer 74.23 mm (2.9224 in.) / 21.70 mm (0.8543 in.)
        Fig 95: Installing Piston (With Springs) To Transaxle Case
        G04487278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL REVERSE CLUTCH ACCUMULATOR PISTON 
    1. Coat 2 new O-rings with ATF, and install them to the reverse accumulator piston.
      NOTE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position.
      Fig 96: Installing O-Rings To Reverse Accumulator Piston
      G04487279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the piston to the transaxle case.
      1. Coat the accumulator piston with ATF.
      2. Install the spring to the piston, and install the piston (with spring) to the transaxle case.
        NOTE: Before installing the spring, check the identification color of the spring.
        Fig 97: Installing Piston (With Spring) To Transaxle Case
        G04487280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard accumulator spring 

        STANDARD ACCUMULATOR SPRING

        Free length Outer diameter Identification Color
        60.96 mm (2.3999 in.) / 14.10 mm (0.5551 in.) Yellow
  61. INSTALL C-3 ACCUMULATOR PISTON 
    1. Coat a new O-ring with ATF, and install it to the C-3 accumulator piston.
      NOTE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position.
      Fig 98: Installing O-Ring To C-3 Accumulator Piston
      G04487281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the piston to the transaxle case and coat the piston with ATF.
      Fig 99: Installing Piston To Transaxle Case
      G04487282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the spring to the C-3 accumulator piston.
    4. Install the spring to the C-3 accumulator piston.
      NOTE: Before installing the spring, check the identification color of the spring.

      Standard accumulator spring 

      STANDARD ACCUMULATOR SPRING

      Free length Outer diameter Color
      72.20 mm (2.8425 in.) / 19.0 mm (0.748 in.) Colorless
      Fig 100: Installing Spring To C-3 Accumulator Piston
      G04487283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSTALL CHECK BALL BODY 
    1. Coat the check ball body with ATF.
    2. Install the check ball body and spring.
      NOTE: Be sure to place the spring in the hole in the check ball body. Be careful of the direction of the parts.
      Fig 101: Installing Check Ball Body And Spring
      G04487284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSTALL BRAKE DRUM GASKET 
    1. Coat a new brake drum gasket with ATF, and install it to the transaxle case.
      NOTE: Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Be careful of the direction of parts.
      Fig 102: Installing Brake Drum Gasket To Transaxle Case
      G04487285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET 
    1. Coat a new transaxle case 2nd brake gasket with ATF, and install it to the transaxle case.
      NOTE: Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Be careful of the direction of parts.
      Fig 103: Installing Transaxle Case 2nd Brake Gasket To Transaxle Case
      G04487286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. INSTALL NO. 1 GOVERNOR APPLY GASKET 
    1. Coat a new governor apply gasket with ATF, and install it to the transaxle case.
      NOTE: Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Be careful of the direction of parts.
      Fig 104: Installing No. 1 Governor Apply Gasket
      G04487287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. INSTALL TRANSMISSION WIRE 
    1. Coat a new O-ring with ATF, and install it to the transmission wire.
      NOTE: Make sure that the O-ring is not twisted, protruded, or pinched when installing the wire transmission to the transaxle case. Apply sufficient ATF to the O-ring before installation.
      Fig 105: Installing O-Ring To Transmission Wire
      G04487288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transmission wire retaining bolt.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      Fig 106: Installing Transmission Wire Retaining Bolt
      G04487289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. CONNECT TRANSMISSION WIRE 
    1. Coat the O-ring of the ATF temperature sensor with ATF.
    2. Apply ATF to the bolt.
    3. Install the ATF temperature sensor with the lock plate and bolt.

      Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf) 

    4. Connect the 7 solenoid valve connectors.
  68. INSTALL TRANSMISSION VALVE BODY ASSEMBLY 
    1. Apply ATF to the 17 bolts.
      Fig 107: Installing ATF Temperature Sensor With Lock Plate And Bolt
      G04487290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. While positioning the manual valve lever position, install the valve body to the transaxle case with the 17 bolts.

      Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

      HINT:

      Each bolt length is indicated below.

      Bolt length: 

      25.0 mm (0.984 in.) for bolt A 

      57.0 mm (2.244 in.) for bolt B 

      41.0 mm (1.614 in.) for bolt C 

      Fig 108: Identifying Bolts
      G04384264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Push the valve body against the accumulator piston spring and the check ball body to install the valve body.
      • When installing the valve body to the transaxle case, do not hold the solenoids.
      • Temporarily tighten the bolts marked with (1) in the illustration first because they are positioning bolts.
  69. INSTALL VALVE BODY OIL STRAINER ASSEMBLY 
    1. Coat a new O-ring with ATF and install it to the oil strainer.
      NOTE: Make sure that the O-ring is not twisted or pinched. Apply sufficient ATF to the O-ring before installation.
    2. Apply ATF to the 3 bolts.
      Fig 109: Installing O-Ring To Oil Strainer
      G04487292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the oil strainer to the valve body with the 3 bolts.

      Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

      Fig 110: Installing Oil Strainer To Valve Body With Bolts
      G04487293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY 
    1. Install the 2 magnets to the oil pan.
      Fig 111: Installing Magnets To Oil Pan
      G04487294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the oil pan and a new oil pan gasket to the transaxle case with the 18 bolts.

      Torque: 7.6 N*m (77 kgf*cm, 67 in.*lbf) 

      NOTE: Completely remove any oil or grease from the contact surface of the transaxle case and the oil pan with the gasket before installing the oil pan to the case.
      Fig 112: Installing Oil Pan Bolts
      G04487295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. INSTALL NO. 1 TRANSAXLE CASE PLUG 
    1. Coat 4 new O-rings with ATF, and install them to the 4 plugs.
    2. Install the 4 plugs to the transaxle case.

      Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

  72. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY 
    1. Coat a new O-ring with ATF, and install it to the cover.
    2. Install the cover with the bolt.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Fig 113: Installing No. 1 Transaxle Case Plug
      G04487296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. INSTALL SPEED SENSOR 
    1. Coat 2 new O-rings with ATF and install them to the 2 sensors.
    2. Install the 2 sensors to the transaxle case with the 2 bolts.

      Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

      Fig 114: Installing Speed Sensor
      G04487297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. INSTALL OIL COOLER INLET TUBE ELBOW 
    1. Coat a new O-ring with ATF, and install it to the elbow.
    2. Install the elbow to the transaxle case.

      Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf) 

      Fig 115: Installing Oil Cooler Inlet Tube Elbow
      G04487298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. INSTALL OIL COOLER OUTLET TUBE ELBOW 
    1. Coat a new O-ring with ATF, and install it to the elbow.
    2. Install the elbow to the transaxle case.

      Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf) 

  76. INSTALL BREATHER PLUG HOSE 
    1. Install the breather plug hose to the transaxle case firmly.
      Fig 116: Installing Oil Cooler Outlet Tube Elbow
      G04487299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY 
    1. Install the switch to the manual valve shaft.
    2. Temporarily install the 2 bolts.
    3. Install a new lock washer and tighten the manual valve shaft nut.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      Fig 117: Installing Park/Neutral Position Switch Bolts
      G04487300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporarily install the control shaft lever. 
      Fig 118: Installing Control Shaft Lever
      G04487301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Turn the lever counterclockwise until it stops, and then turn it clockwise 2 notches. 
    6. Remove the control shaft lever. 
      Fig 119: Turning Lever Counterclockwise
      G04487302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Align the groove and neutral basic line. 
    8. Hold the switch in this position and tighten the 2 bolts. 

      Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 

      Fig 120: Aligning Groove And Neutral Basic Line
      G04487303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Using a screwdriver, stake the nut with the lock washer.
      Fig 121: Staking Nut With Lock Washer
      G04487304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Install the control shaft lever with the washer and nut.

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

  78. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY 
    1. Coat a new O-ring with ATF and install it to the speedometer driven hole cover.
    2. Install the bolt and hole cover to the transaxle.

      Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 

      Fig 122: Installing Control Shaft Lever With Washer And Nut
      G04487305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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