Automatic Transaxle Unit: Reassembly

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

BEARING POSITION

Fig 1: Identifying Bearing Position

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard bearing position

THRUST BEARING DIAMETER INSIDE / OUTSIDE

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.)	29.9 mm (1.177 in.) / 55.5 mm (2.185 in.)
C	-	33.85 mm (1.3327 in.) / 52.2 mm (2.055 in.)	-
D	-	23.5 mm (0.925 in.) / 44.0 mm (1.732 in.)	-
E	-	36.3 mm (1.429 in.) / 52.2 mm (2.055 in.)	34.5 mm (1.358 in.) / 48.5 mm (1.909 in.)
F	-	34.6 mm (1.362 in.)/ 52.2 mm (2.055 in.)	-
G	40.3 mm (1.587 in.) / 58.0 mm (2.283 in.)	38.6 mm (1.520 in.) / 60.0 mm (2.362 in.)	38.6 mm (1.520 in.) / 58.0 mm (2.283 in.)
H	-	53.6 mm (2.110 in.) / 69.6 mm (2.740 in.)	-
I	-	33.8 mm (1.331 in.) / 48.2 mm (1.898 in.)	30.3 mm (1.193 in.)/46.0 mm (1.811 in.)
J	-	53.6 mm (2.110 in.) / 70.18 mm (2.763 in.) or 69.6 mm (2.740 in.)	-

INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
1. Install the apply tube and 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: Identifying Differential Gear Lube Apply Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING
1. Install a new oil seal ring to the transaxle housing.
  
  Fig 3: Identifying Oil Seal Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING
1. 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.
  
  Fig 4: Identifying Underdrive Cylindrical Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING
1. Install 2 new oil seal rings to the transaxle.
  
  Fig 5: Identifying Oil Seal Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE BRAKE PISTON
1. Wind a vinyl tape around SST at the place 4.0 mm (0.157 in.) above from the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 in.)
  SST 09950-60010(09951-00320)
  
  NOTE: Clean SST to remove deposited oil before winding a vinyl tape.
  
  Fig 6: Identifying Winding Vinyl Tape Around SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in the needle-roller bearing to the transaxle until the wound vinyl tape contacts the transaxle case.
  SST 09950-60010(09951-00320), 09950-70010 (09951-07100)
  
  Fig 7: Identifying Needle-Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat 2 new Q-rings with ATF, and install them to the underdrive brake piston.
  
  Fig 8: Identifying O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the underdrive brake piston to the transaxle.
  
  Fig 9: Identifying Underdrive Brake
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, a snap ring expander and press, press in the piston return spring and snap ring to the transaxle.
  SST 09387-00020
  
  NOTE: Do not apply excessive pressure.
  
  Fig 10: Identifying Piston Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 BREATHER PLUG
INSTALL COUNTER DRIVE GEAR HOLE SNAP RING
1. Using a screwdriver, press in the snap ring to the transaxle.
  
  Fig 11: Identifying Snap Ring To Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COUNTER DRIVE GEAR
1. Using SST and a press, press in the 2 bearings outer races to the transaxle.
  SST 09950-60020 (09951-00890), 09950-70010 (09951-07150)
  
  Fig 12: Identifying Bearings Outer Races
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in the tapered roller bearing to the counter drive gear until the bearing race contacts with the snap ring.
  NOTE: Do not apply excessive pressure.
  
  SST 09649-17010
  
  Fig 13: Identifying Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, install the counter drive gear and bearing to the transaxle.
  SST 09950-70010 (09951-07150), 09950-60020 (09951-00750)
  
  NOTE: Do not apply excessive pressure.
  
  Fig 14: Identifying Counter Drive Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST AND REVERSE BRAKE PISTON
1. Coat 2 new O-rings with ATF.
2. Install the 2 O-ring to the 1st and reverse brake piston.
3. Coat the 1st and reverse brake piston with ATF, and install it to the transaxle.
  
  Fig 16: Identifying 1st And Reverse Brake Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
1. Using SST, a press and snap ring expander, press the piston return spring and snap ring to the transaxle.
  SST 09387-00070
  NOTE:
  - Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, preventing the spring sheet from being deform.
  - Do not expand the snap ring excessively.
    
    Fig 17: Identifying Snap Ring Expander
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT PLANETARY RING GEAR
1. Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.
  
  Fig 18: Identifying Front Planetary Ring Gear And Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT PLANETARY GEAR ASSEMBLY
1. Install the front planetary gear assembly to the brake hub.
  
  Fig 19: Identifying Front Planetary Gear Assembly To Brake Hub
  Courtesy 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.
  
  Fig 20: Identifying Front Planetary Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the washer, as shown in the illustration.
  
  Fig 21: Identifying Front Planetary Gear Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, install the nut.
  SST 09387-00030,09387-00080
  
  Torque: 280 N*m (2,855 kgf*cm, 206 ft.*lbf)
  
  Fig 22: Identifying Nut
  Courtesy 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 within the specified value, gradually tighten the nut until it reaches the specified value.
  SST 09387-00080
  
  Torque: 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
  
  0.3 to 0.5 N*m (3.1 to 5.1 kgf*cm, 27 to 4.4 in.*lbf) for used
  
  Fig 23: Identifying Turning Torque Of Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
6. Using a chisel and hammer, stake the front planetary gear washer.
  
  Fig 24: Identifying Front Planetary Gear Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL INPUT SUN GEAR

Install the 2 thrust bearings, bearing race and front planetary sun gear to the front planetary gear.

Standard bearing and race diameter

STANDARD BEARING AND RACE DIAMETER

Item	Inside	Outside
Bearing	34.6 mm (1.362 in.)	52.2 mm (2.055 in.)
Race	40.3 mm (1.587 in.)	58.0 mm (2.283 in.)
Bearing	38.6 mm (1.52 in.)	60.0 mm (2.362 in.)

Fig 25: Identifying Thrust Bearings, Bearing Race And Front Planetary Sun Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR PLANETARY GEAR ASSEMBLY

Coat the bearing race with ATF, and install it to the rear planetary gear assembly.

Standard bearing race diameter

STANDARD BEARING RACE DIAMETER

Item	Inside	Outside
Race	38.6 mm (1.520 in.)	58.0 mm (2.83 in.)

Fig 26: Identifying Rear Planetary Gear Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the No. 2 thrust washer.

Fig 27: Identifying No. 2 Thrust Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the rear planetary gear to the rear planetary ring gear.

Fig 28: Identifying Rear Planetary Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a screwdriver, install the snap ring.

Fig 29: Identifying Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC

Install the 5 plates and 5 discs.
Install in order:

P - D - P - D - P - D - P - D - P - D

HINT:

P = Plate

D = Disc

Fig 30: Identifying Plate And Disc
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a vernier caliper, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder arid transaxle (Dimension A).

Select an appropriate flange so that the pack clearance will meet the specified value.

0.745 to 1:21 mm (0.0293 to 0.0476 in.)

Fig 31: Identifying Distance Between Disc Surface And Contact Surface Of 2nd Brake Cylinder Arid Transaxle

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Piston stroke = Dimension A - Flange thickness

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.)

Install the flange.

Fig 32: Identifying Flange
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL 2ND BRAKE PISTON ASSEMBLY
1. Install the 2nd brake piston to the transaxle.
2. Install the snap ring and measure the inside diameter.
  Standard inside diameter:
  
  More than 167 mm (6.57 in.)
  NOTE:
  - Because the taper snap ring has the positioning direction, check it when installing.
  - When the diameter does not satisfy the specified value, replace the snap ring with a new one.
INSTALL 1-WAY CLUTCH SLEEVE OUTER
1. Install the 1-way clutch outer sleeve to the 2nd brake cylinder.
  NOTE: Check the positioning direction of the outer sleeve.
  
  Fig 34: Identifying 1-Way Clutch Outer Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL 1-WAY CLUTCH ASSEMBLY

Install the inner race to the 1-way clutch.
NOTE: Check the direction of the inner race.

Fig 35: Identifying Inner Race
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check the rotating direction of the 1 -way clutch for the lock or free operation, as shown in illustration.

Fig 36: Identifying Rotating Direction Of 1 -Way Clutch
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the 1-way clutch and bearing to the 1-way clutch sleeve outer.

Standard bearing diameter

STANDARD BEARING DIAMETER

Item	Inside	Outside
Bearing	53.6 mm (2.110 in.)	69.6 mm (2.740 in.)

Fig 37: Identifying 1-Way Clutch And Bearing To 1-Way Clutch Sleeve Outer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Install the thrust bearing properly so that no-colored race will be visible.

INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

Coat the No. 1 thrust washer with petroleum jelly, and install it onto the rear planetary sun gear.

Fig 38: Identifying No. 1 Thrust Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Coat the bearing with petroleum jelly, and install it onto the rear planetary sun gear.

Standard bearing diameter

STANDARD BEARING DIAMETER

Item	Inside	Outside
Bearing	33.8 mm (1.331 in)	48.2 mm (1.898 in.)

Fig 39: Identifying Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the rear planetary sun gear to the rear planetary gear.

Fig 40: Identifying Rear Planetary Sun Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL 2ND BRAKE CLUTCH DISC

Install the 3 discs and 3 plates to the transaxle.
Standard install in order:

P - D - P - D - P - D

HINT:

P = Plate

D = Disc

Fig 41: Identifying Discs And Plates To Transaxle
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Temporarily install the snap ring.
Using a vernier caliper, measure the distance between the disc surface and snap ring surface.

Fig 42: Identifying Distance Between Disc Surface And Snap Ring Surface

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select an appropriate flange so that the pack clearance will meet the specified value.

Standard pack clearance:

0.50 to 0.91 mm (0.0197 to 0.0358 in.)

HINT:

Piston stroke = Clearance - 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	-

Temporarily remove the snap ring, attach the selected flange and restore the snap ring.
NOTE: Secure the snap ring so that its gap is visible through the groove of the transaxle case.

Fig 43: Identifying Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL DIRECT CLUTCH

Install the bearing race to the direct clutch.

Standard bearing race diameter

STANDARD BEARING RACE DIAMETER

Item	Inside	Outside
Bearing race	30.3 mm (1.193 in.)	46.0 mm (1.811 in.)

Fig 44: Identifying Bearing Race To Direct Clutch

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the direct clutch and thrust bearing to the rear planetary sun gear.
NOTE: The disc in the direct clutch should completely mate with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed.

Fig 45: Identifying Direct Clutch And Thrust Bearing To Rear Planetary Sun Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Clean the connector part of the transaxle case and rear cover.
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 B).

Fig 46: Identifying Distance Between Transaxle Case And Straightedge
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Measure the 2 places of the rear cover as shown in the illustration. Calculate a dimension C using the following formula.
HINT:

Dimension C = Dimension (1) - Dimension (2)

Fig 47: Identifying Rear Cover Dimension
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install it.

End play:

0.198 to 0.936 mm (0.00780 to 0.03685 in.)

NOTE: Make sure that the colored race side is facing the direct clutch assembly.

HINT:

End play = Dimension C - Dimension B

Standard bearing thickness and diameter

STANDARD BEARING THICKNESS AND DIAMETER

Thickness	Inside	Outside
3.58 mm (0.1409 in.)	53.6 mm (2.110 in.)	69.6 mm (2.740 in.)
3.88 mm (0.1528 in.)	53.6 mm (2.110 in.)	70.18 mm (2.768 in.)

INSTALL NO. 1 GOVERNOR APPLY GASKET
1. Install 2 new governor apply gaskets.
  
  Fig 48: Locating Governor Apply Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT CLUTCH APPLY TUBE
1. Install the clamp to the front clutch apply tube.
  NOTE: Make sure to install the clamp to the apply pipe before installing the apply pipe to the transaxle case. This prevents the apply pipe from being deformed or damaged.
  
  Fig 49: Identifying Front Clutch Apply Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE APPLY TUBE
1. Install the clamp to the brake apply tube.
  NOTE: Make sure to install the clamp to the apply pipe before installing the apply pipe to the transaxle case. This prevents the apply pipe from being deformed or damaged.
  
  Fig 50: Identifying Brake Apply Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 apply tubes and to the transaxle with the bolt.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  NOTE: Each pipe should be securely inserted until it reaches the stopper.
  
  Fig 51: Identifying Apply Tubes And To Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
INSTALL TRANSAXLE REAR COVER SUBASSEMBLY
1. Using SST and a press, press in the bearing.
  SST 09950-60010 (09951-00230, 09952-06010)
  
  Standard depth:
  
  12.05 to 12.75 mm (0.4744 to 0.5020 in.)
  NOTE:
  - Face the inscribed mark side of the bearing race up.
  - Repeat the press-fit until the specified value is obtained.
  Fig 53: Identifying Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply adhesive to the 2 screws.
  Adhesive:
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
3. Using a T30 "TORX" socket wrench, install the transaxle rear cover plate with the 2 screws.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
  
  Fig 54: Identifying Transaxle Rear Cover Plate With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Coat 2 new oil seal rings with ATF, and install them to the transaxle rear cover.
  
  Fig 55: Identifying Oil Seal Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover or the transaxle.
6. Apply FIPG to the cover.
  Seal packing:
  
  Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
7. Coat the needle roller bearing with ATF.
8. Apply adhesive to the threads of the bolts labeled A.
  Adhesive:
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
  
  Fig 57: Identifying Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Install 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 bolt
  
  SST 09950-60010 (09951-00230, 09952-06010)

INSTALL NO. 2 UNDERDRIVE CLUTCH DISC

Install the 3 discs and 3 plates to the transaxle.
Install in order:

P - D - P - D - P - D

HINT:

D = Disc

P = Plate

Fig 58: Identifying Discs And Plates To Transaxle
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a screwdriver, install the snap ring.

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:

1.59 to 2.20 mm (0.0626 to 0.0866 in.)

HINT:

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

Fig 59: Identifying Underdrive Brake Pack Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard flange thickness

STANDARD FLANGE THICKNESS

Mark	Thickness	Mark	Thickness
1	3.0 mm (0.118 in.)	3	3.4 mm (0.134 in.)
2	3.2 (0.126 in.)	-	-

Temporarily remove the snap ring and attach the flange. Restore the snap ring.

INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY (See INSPECTION )
INSTALL UNDERDRIVE 1 WAY CLUTCH ASSEMBLY
1. Install the outer race retainer to the 1-way clutch.
  
  Fig 60: Identifying Outer Race Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 1 -way clutch to the transaxle.
  NOTE: Make sure that the mark on the 1-way clutch outer race is visible.
  
  Fig 61: Identifying 1 -Way Clutch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, install the snap ring to the transaxle.
  
  Fig 62: Identifying Snap Ring To Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL UNDERDRIVE CLUTCH ASSEMBLY

Coat the bearing and bearing race with petroleum jelly, and install them onto the underdrive clutch.

Standard race diameter

STANDARD RACE DIAMETER

Item	Inside	Outside
Bearing	37.73 mm (1.4854 in.)	58.0 mm (2.283 in.)
Race	29.9 mm (1.177 in.)	55.5 mm (2.185 in.)

Install the underdrive clutch to the transaxle.

Fig 63: Identifying Underdrive Clutch To Transaxle
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL UNDERDRIVE PLANETARY GEAR
1. Install the pawl pin and spring to the parking lock pawl.
  
  Fig 64: Identifying Pawl Pin And Spring To Parking Lock Pawl
  Courtesy 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: Identifying Parking Lock Pawl, Shaft And Spring To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the underdrive planetary gear to the transaxle.
  NOTE: Engage all the discs of underdrive clutch and the hub splines of the underdrive planetary gear firmly and assemble them securely.
  
  Fig 66: Identifying Underdrive Planetary Gear To Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the parking lock pawl shaft.
  
  Fig 67: Identifying Parking Lock Pawl Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the pawl shaft clamp with the bolt.
  Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
  
  Fig 68: Identifying Pawl Shaft Clamp With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a straightedge and vernier calipers as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and contact surface of the transaxle and housing (Dimension D).
  NOTE: Make a note of dimension D as it is necessary for the following process.
  
  Fig 69: Identifying Gap Between Top Of Differential Drive Pinion In Underdrive Planetary Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. As shown in the illustration, measure the 2 places of the transaxle housing. Calculate the dimension E using the formula.
  NOTE: Make a note of dimension E as it is necessary for the following process.
  
  HINT:
  
  Dimension E = Dimension (1) - Dimension (2)
  
  Fig 70: Identifying Places Of Transaxle Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL MULTIPLE DISC CLUTCH HUB

Install the bearing race to the transaxle while checking its direction.

Standard bearing race diameter

STANDARD BEARING RACE DIAMETER

Item	Inside	Outside
Bearing race	34.5 mm (1.358 in.)	48.5 mm (1.909 in.)

Fig 71: Identifying Bearing Race To Transaxle

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Coat the thrust bearing and race with petroleum jelly, and install them onto the multiple disc clutch hub.

Standard thrust bearing and race diameter

STANDARD THRUST BEARING AND RACE DIAMETER

Item	Inside	Outside
Bearing	36.3 mm (1.429 in.)	52.2 mm (2.055 in.)

Fig 72: Installing Thrust Bearing Onto Multiple Disc Clutch Hub

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the bearing to the multiple clutch hub.

Standard bearing diameter

STANDARD BEARING DIAMETER

Item	Inside	Outside
Bearing	23.5 mm (0.925 in.)	44.0 mm (1.732 in.)

Install the forward clutch hub to the transaxle.

Fig 73: Identifying Forward Clutch Hub To Transaxle
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FORWARD CLUTCH ASSEMBLY

Install the thrust bearing to the forward clutch.

Standard bearing diameter

STANDARD BEARING DIAMETER

Item	Inside	Outside
Bearing	33.85 mm (1.3327 in.)	52.2 mm (2.055 in.)

NOTE: Install the thrust bearing properly so that the race "B" will be visible.

Fig 74: Identifying Thrust Bearing

Install the forward clutch to the multiple clutch hub.
NOTE: Align the splines of all discs in the forward clutch with those of multiple clutch hub to assemble them securely.

Fig 75: Identifying Forward Clutch To Multiple Clutch Hub
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL OVERDRIVE BRAKE GASKET
1. Install 2 new overdrive brake gaskets.
  
  Fig 76: Identifying Overdrive Brake Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL GEAR ASSEMBLY
1. Install the differential gear to the transaxle.
  
  Fig 77: Identifying Differential Gear To Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE
1. Install the thrust bearing race to the underdrive planetary gear.
  
  Fig 78: Identifying Thrust Bearing Race To Underdrive Planetary Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL THRUST NEEDLE ROLLER BEARING

Calculate the end play value using the following formula and values of Dimensions D and E that were measured when installing cylindrical roller bearing and underdrive planetary gear. Select an appropriate underdrive planetary gear thrust bearing race No. 2 which satisfies the specified end play value, and instal it.

End play:

0.498 to 0.993 mm (0.0196 to 0.0390 in.)

Fig 79: Identifying Thrust Needle Roller Bearing

HINT:

End play = Dimension E - Dimension D - thrust bearing thickness 3.28 mm (0.1291 in.) - underdrive thrust bearing race thickness.

Standard race thickness

STANDARD RACE THICKNESS

E - D	Thickness
Less than 7.64 mm (0.3008 in.)	3.5 mm (0.138 in.)
7.64 mm (0.3008 in.)	3.8 m (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 (3.3449 in.)
Bearing race	56.4 mm (2.220 in.)	83.0 mm (3.268 in.)

INSTALL OIL PUMP ASSEMBLY
1. Install the oil pump to the transaxle with the 7 bolts.
  Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)
  
  Fig 80: Identifying Oil Pump To Transaxle With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the O-ring of the oil pump with ATF.
  
  Fig 81: Identifying Oil Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE HOUSING
1. Remove any packing material and be careful not to get oil on the contacting surface of the transaxle housing.
2. Apply FIPG to the transaxle.
  Seal packing:
  
  Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
  
  Fig 82: Identifying FIPG To Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the transaxle housing to the transaxle with the 16 bolts.
  Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) for bolt A
  
  29 N*m (296 kgf*cm, 21 ft.*lbf) for bolt B and C
  
  HINT:
  
  Each bolt length is indicated below.
  
  Fig 83: Locating Transaxle Housing To Transaxle With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Bolt length:
  
  50 mm (1.969 in.) for bolt A
  
  50 mm (1.969 in.) for bolt B
  
  42 mm (1.654 in.) for bolt C
  
  NOTE: Because the bolt labeled A are seal bolts, apply seal packing to new bolts and tighten them within 10 minutes after application.
  
  Seal packing:
  
  Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
INSTALL NO. 1 TRANSAXLE CASE PLUG
1. Install 2 new O-rings to the 2 plugs.
2. Install the 2 plugs to the transaxle housing.
  Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
  
  Fig 84: Identifying Plugs To Transaxle Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INPUT SHAFT END PLAY (See INSPECTION )
FIX AUTOMATIC TRANSAXLE ASSEMBLY

Fig 85: Identifying Automatic Transaxle Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
1. Coat a new oil seal with ATF.
2. Install the oil seal to the transaxle.
  
  Fig 86: Identifying Oil Seal To Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PARKING LOCK ROD SUB-ASSEMBLY
1. Install the parking lock rod to the manual valve lever.
  
  Fig 87: Identifying Parking Lock Rod To Manual Valve Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY
1. Install a new spacer and manual valve lever shaft to the transaxle.
  
  Fig 88: Identifying Spacer And Manual Valve Lever Shaft To Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch and hammer, tap in a new pin.
  
  Fig 89: Identifying Tapping Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn the spacer and lever shaft to align the small hole for locating 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.
INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING
1. Using needle-nose pliers, install the retainer spring.
  
  Fig 91: Identifying Retainer Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
  
  Bolt length:
  
  25 mm (0.984 in.)
  
  Fig 92: Identifying Parking Lock Pawl Bracket With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL DETENT SPRING SUBASSEMBLY
1. Install the manual detent spring with the 2 bolts.
  NOTE: Make sure to install the manual detent spring and cover in this order.
  
  Torque: 20 N*m (204 kgf*cm, 16 ft.*lbf) for bolt A
  
  12 N*m (122 kgf*cm, 9 ft.*lbf) for bolt B
  
  HINT:
  
  Each bolt length is indicated below.
  
  27 mm (1.063 in.) for bolt A
  
  16 mm (0.630 in.) for bolt B
  
  Fig 93: Identifying Manual Detent Spring With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL B-3 ACCUMULATOR PISTON

Coat a new O-ring with ATF, and install it to the B-3 accumulator piston.

Fig 94: Locating B-3 Accumulator Piston O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Coat the piston with ATF, install it to the transaxle.

Standard accumulator spring

STANDARD ACCUMULATOR SPRING FREE LENGTH OUTER DIAMETER

Spring	Free length Outer diameter	Color
B-3 Inner	60.24 mm (2.3716 in.) 15.9 (0.626 in.)	Yellowish green
B-3 Outer	74.61 mm (2.9374 in.) 21.7 mm (0.854 in.)	Blue

Fig 95: Identifying Piston To Transaxle

INSTALL C-1 ACCUMULATOR PISTON

Coat 2 new O-rings with ATF, and install them to the C-1 accumulator piston.

Fig 96: Locating C-1 Accumulator Piston O-Rings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Coat the piston with ATF, and install it to the transaxle.

Standard accumulator spring

STANDARD ACCUMULATOR SPRING - FREE LENGTH OUTER DIAMETER

Spring	Free length Outer diameter	Color
C-1 81.53 mm (3.2098 in.)	18.5 mm (0.728 in.)	Pink

Fig 97: Identifying Piston To Transaxle

INSTALL C-3 ACCUMULATOR PISTON

Coat a new O-ring with ATF, and install it to the C-3 accumulator piston.

Fig 98: Locating C-3 Accumulator Piston O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Coat the piston with ATF, install it to the transaxle case.

Standard accumulator spring

STANDARD ACCUMULATOR SPRING - FREE LENGTH OUTER DIAMETER

Spring	Free length Outer diameter	Color
C-3 90.49 mm (3.5626 in.)	19.2 mm (0.756 in.)	White

Fig 99: Identifying Coating Piston With ATF

Install the spring from the C-3 accumulator piston:

Fig 100: Identifying Spring From C-3 Accumulator Piston
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CHECK BALL BODY
1. Install the check ball body and spring.
  
  Fig 101: Identifying Check Ball Body And Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE DRUM GASKET
1. Coat a new brake drum gasket with ATF, and install it to the transaxle.
  
  Fig 102: Locating Brake Drum Gasket To Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
1. Coat a new transaxle case 2nd brake gasket with ATF, and install it to the transaxle.
  
  Fig 103: Locating Transaxle Case 2Nd Brake Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 GOVERNOR APPLY GASKET
1. Coat a new governor apply gasket No. 1 with ATF, and install it to the transaxle.
  
  Fig 104: Locating No. 1 Governor Apply Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION WIRE
1. Coat a new O-ring with ATF, and install it to the transaxle solenoid wire.
  
  Fig 105: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the solenoid wire retaining bolt
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  Fig 106: Locating Solenoid Wire Retaining Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION VALVE BODY ASSEMBLY
1. Align the groove of the manual valve with the pin of lever.
2. Install the 17 bolts.
  Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
  NOTE:
  - Push the valve body against the accumulator piston spring and the check ball body to install it.
  - Tighten the bolts marked by * in the illustration first temporarily because they are positioning bolts.
  HINT:
  
  Each bolt length is indicated below.
  
  Fig 107: Identifying Transmission Valve Body Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Bolt length:
  
  25 mm (0.984 in.) for bolt A
  
  41 mm (1.614 in.) for bolt B
  
  45 mm (1.771 in.) for bolt C
3. Connect the 5 solenoid connectors.
4. Coat the O-ring of the temperature sensor with ATF.
5. Install the ATF temperature sensor with the lock plate and bolt.
  Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf)
  
  Fig 108: Identifying ATF Temperature Sensor With Lock Plate And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE BODY OIL STRAINER ASSEMBLY
1. Coat a new O-ring with ATF.
2. Install the O-ring to the oil strainer.
  
  Fig 109: Locating O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the oil strainer with the 3 bolts.
  Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
  
  Fig 110: Locating Oil Strainer Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY
1. Install the 3 magnets in the oil pan.
2. Install a new oil pan gasket to the oil pan.
3. Install the oil pan to the transaxle with the 18 bolts.
  Torque: 7.6 N*m (77 kgf*cm, 67 in.*lbf)
  
  NOTE: Because the bolts are seal bolts, apply seal packing to new bolts and tighten them within 10 minutes after application.
  
  Fig 112: Identifying Oil Pan To Transaxle With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
  
  Fig 113: Identifying Plugs To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPEED SENSOR
1. Coat 2 new O-rings with ATF, and install them to the 2 sensors.
2. Install the 2 sensors with the 2 bolts.
  Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
  
  Fig 114: Identifying Sensors With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL COOLER INLET TUBE UNION
1. Coat a new O-ring with ATF, and install it to the union.
2. Install the union to the transaxle.
  Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf)
INSTALL OIL COOLER OUTLET TUBE UNION
1. Coat a new O-ring with ATF, and install it to the union.
2. Install the union to the transaxle.
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
INSTALL BREATHER PLUG HOSE
INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
1. Install the park/neutral position switch to the manual valve shaft.
2. Temporarily install the 2 bolts.
3. Install a new lock plate and tighten the manual valve shaft nut.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
4. Temporarily install the control shaft lever.
  
  Fig 118: Identifying Control Shaft Lever
  Courtesy 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.
7. Align the groove with 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)
9. Using a screwdriver, stake the nut with the lock plate.
  
  Fig 121: Identifying Nut With Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Install the control shaft lever with the washer and nut.
  Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
  
  Fig 122: Locating Control Shaft Lever With Washer And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002