Automatic Transaxle Unit: Reassembly

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BEARING POSITION

Fig 1: Identifying Bearing Position

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard bearing position

BEARING POSITION REFERENCE

Mark	Front Race Diameter Inside / Outside	Thrust Bearing Diameter Inside / Outside	Rear Race Diameter Inside / Outside
A	-	53.0 mm (2.087 in.) / 78.2 mm (3.079 in.)	52.1 mm (2.051 in.) / 75.5 mm (2.972 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 (1.492 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	-	33.7 mm (1.327 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 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 tube to the stopper.
  
  Fig 2: Identifying Transaxle Apply Tube Clamp Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 BREATHER PLUG
INSTALL COUNTER DRIVE GEAR HOLE SNAP RING
1. Using a screwdriver, install the hole snap ring to the transaxle.
  
  Fig 3: Identifying Hole Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COUNTER DRIVE GEAR
1. Using SST and a press, press in the 2 counter drive gear bearings outer races to the transaxle.
  NOTE:
  - Press-fit the bearing race until it contacts the snap ring.
  - Do not apply excessive pressure.
  SST 09950-60020 (09951-00890, 09951-07150)
  
  Fig 4: Identifying Pressing In Counter Drive Gear 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.
  SST 09649-17010
  NOTE:
  - Press-fit the bearing inner race until it contacts the counter drive gear.
  - Do not apply excessive pressure.
    
    Fig 5: Identifying Pressing In Tapered Roller Bearing To Counter Drive Gear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, press in the counter drive gear and bearing to the transaxle.
  SST 09950-60020 (09951-00890), 09950-70010 (09951-07150)
  
  NOTE: Do not apply excessive pressure.
  
  Fig 6: Identifying Pressing In Counter Drive Gear And Bearing To Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1 ST 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.
  
  Fig 7: Identifying 1st And Reverse Brake Piston O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the 1st and reverse brake piston with ATF, and install it to the transaxle.
  
  Fig 8: Identifying 1st And Reverse Brake Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 1st and reverse brake return spring to the 1st and reverse brake piston.
  
  Fig 9: Identifying 1st And Reverse Brake Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, a press and snap ring expander, press the piston return spring and snap ring to the transaxle.
  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 10: Identifying Piston Return Spring And Snap Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT PLANETARY RING GEAR
1. Using a screwdriver, install the front planetary ring gear and brake hub snap ring to the brake hub.
  
  Fig 11: Identifying Front Planetary Ring Gear And Brake Hub Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT PLANETARY GEAR ASSEMBLY
1. Install the front planetary gear to the brake hub.
  
  Fig 12: Identifying Front Planetary Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press-fit the front planetary gear.
  NOTE: Do not apply excessive pressure to it.
  
  Fig 13: Identifying Front Planetary Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the front planetary gear washer, as shown in the illustration.
  
  Fig 14: 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 15: 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 09950-60010 (09951-00400), 09950-70010 (09951-07100), 09387-00030, 09387-00080
  
  Fig 16: Identifying Turning Torque Of Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: Turning torque at 60 rpm
  
  0.5 to 1.0 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, 2.7 to 4.4 in.*lbf) for used
6. Using a chisel and hammer, stake the front planetary gear washer.
  
  Fig 17: 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 planetary gear.

Standard bearing race diameter

BEARING RACE DIAMETER SPECIFICATION

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 (1.520 in.)	60.0 mm (2.362 in.)

Fig 18: 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.

Standard bearing race diameter

BEARING RACE DIAMETER SPECIFICATION

Item	Inside	Outside
Race	38.6 mm (1.520 in.)	58.0 mm (2.283 in.)

Fig 19: Identifying Rear Planetary Gear Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the planetary carrier thrust washer to the planetary gear.

Fig 20: Identifying Planetary Carrier Thrust Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the rear planetary gear to the rear planetary ring gear.

Fig 21: Identifying Rear Planetary Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a screwdriver, install the snap ring to the brake hub.

Fig 22: 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 23: 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 and transaxle (Dimension A).

Fig 24: Identifying Distance Between Disc Surface And Contact Surface Of 2nd Brake Cylinder Arid Transaxle

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select an appropriate flange so that the piston stroke will meet the specified value.

Pack clearance:

1.02 to 1.21 mm (0.0402 to 0.0476 in.)

HINT:

Piston stroke = Dimension A - Flange thickness

Standard flange thickness

FLANGE THICKNESS SPECIFICATION

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 25: Identifying Flange

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE
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 26: 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 27: Identifying 1-Way Clutch 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 28: 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 outer race sleeve.

Standard bearing diameter

BEARING DIAMETER SPECIFICATION

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

Fig 29: 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 planetary carrier thrust washer with petroleum jelly, and install it onto the rear planetary sun gear.

Fig 30: Identifying No. 1 Planetary Carrier 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

BEARING DIAMETER SPECIFICATION

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

Fig 31: Identifying Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 32: 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.
Install in order:

P - D - P - D - P - D

HINT:

P = Plate

D = Disc

Fig 33: Identifying Discs And Plates
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 34: Identifying Distance Between Disc Surface And Snap Ring Surface

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select an appropriate flange so that the piston stroke will meet the specified value.

Standard pack clearance:

0.62 to 0.91 mm (0.0244 to 0.0358 in.)

HINT:

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

Standard flange thickness

FLANGE THICKNESS SPECIFICATION

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

INSTALL DIRECT CLUTCH

Install the bearing race to the direct clutch.

Standard bearing diameter

BEARING DIAMETER SPECIFICATION

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

Fig 36: Identifying Bearing Race

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 37: Identifying Direct Clutch And Thrust Bearing
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 38: 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 and calculate a dimension C using the following formula.

Fig 39: Identifying End Play Value
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

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

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 (0.00800 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

BEARING THICKNESS AND DIAMETER SPECIFICATION

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 (2.763 in.)

INSTALL NO. 1 GOVERNOR APPLY GASKET
1. Install 2 new apply gaskets to the transaxle.
  
  Fig 40: Identifying No. 1 Governor Apply Gasket
  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 41: 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 42: Identifying Brake Apply Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 apply tubes 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 43: Identifying Apply Tubes
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 TRANSAXLE CASE PLUG

Fig 44: Identifying No. 1 Transaxle Case Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install 2 new 0-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, 09951-00350)
  
  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 45: Identifying Pressing In 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, install the transaxle rear cover plate with the 2 screws.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
  
  Fig 46: 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 47: Identifying Oil Seal
  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 seal packing to the cover.
  Seal packing:
  
  Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
  
  Fig 48: Identifying Seal Packing Applying Area To Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 49: Identifying Adhesive Applying Area To Threads Of 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
INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING
1. Install 2 new oil seals to the transaxle.
  
  Fig 50: Identifying Underdrive Clutch Drum Oil Seal Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE BRAKE PISTON
1. Wind a vinyl tape around SST at the 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 09550-60010 (09951-00320)
  
  NOTE: Clean SST to remove deposited oil before winding a vinyl tape.
  
  Fig 51: Identifying 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 09550-60010 (09951-00320), 09950-70010 (09951-07100), 09387-00020
  
  Fig 52: Identifying SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat 2 new O-rings with ATF, and install them to the underdrive brake piston.
  
  Fig 53: Identifying Underdrive Brake Piston O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the underdrive brake piston to the transaxle.
  
  Fig 54: Identifying Underdrive Brake Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY
1. Install the underdrive brake return spring to the underdrive brake piston.
  
  Fig 55: Identifying Underdrive Brake Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, a snap ring expander and press, press the return spring and install the snap ring to the transaxle.
  SST 09387-00020
  
  NOTE: Do not apply excessive pressure.
  
  Fig 56: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 58: Identifying Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a dial indicator, measure the underdrive brake piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm² , 57 psi).

Standard piston stroke:

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.

Standard flange thickness

FLANGE THICKNESS SPECIFICATION

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

Fig 59: Identifying Underdrive Brake Piston Stroke

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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 underdrive clutch assembly to the 1-way clutch. Rotate the underdrive clutch to check the rotating direction for the lock or free operation.
  
  Fig 61: Identifying Underdrive 1-Way Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 1-way clutch to the transaxle.
  NOTE: Make sure that the mark on the 1 -way clutch outer race is visible.
  
  Fig 62: Identifying 1-Way Clutch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a screwdriver, install the snap ring to the transaxle.
  
  Fig 63: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL UNDERDRIVE CLUTCH

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

Standard race diameter

RACE DIAMETER SPECIFICATION

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.)

Fig 64: Identifying Underdrive Clutch

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the underdrive clutch assembly to the transaxle.

INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY
1. Install the parking lock pawl pin and torsion spring to the parking lock pawl.
  
  Fig 65: Identifying Parking Lock Pawl Pin And Torsion Spring
  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 66: Identifying Parking Lock Pawl
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the underdrive planetary gear assembly to the transaxle.
  NOTE: Engage all the discs of the underdrive clutch and hub splines of the underdrive planetary gear assembly firmly and assemble them securely.
  
  Fig 67: Identifying Underdrive Planetary Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the parking lock pawl shaft.
  
  Fig 68: 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 69: Identifying Pawl Shaft Clamp With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. 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 contact surface of the transaxle and housing (Dimension D).
  NOTE: Note down the dimension D as it is necessary for the following process.
  
  Fig 70: Identifying Gap Between Top Of Differential Drive Pinion
  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: Note down the dimension E as it is necessary for the following process.
  
  HINT:
  
  Dimension E = Dimension (1) - Dimension (2)
  
  Fig 71: Identifying Dimension E
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT MULTIPLE DISC CLUTCH CLUTCH HUB (See INSPECTION )

INSTALL MULTIPLE DISC CLUTCH CLUTCH HUB

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

Standard bearing diameter

BEARING DIAMETER SPECIFICATION

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

Fig 72: Identifying Bearing Race To Transaxle

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard thrust bearing and race diameter

THRUST BEARING AND RACE DIAMETER SPECIFICATION

Item	Inside	Outside
Bearing	36.3 mm (1.429 in.)	52.25 mm (2.055 in.)

Fig 73: Identifying Thrust Bearing And Race

Install the input shaft thrust bearing to the multiple clutch hub.

Standard bearing diameter

BEARING DIAMETER SPECIFICATION

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

Fig 74: Identifying Forward Clutch Hub

Install the forward clutch hub to the transaxle.

INSTALL FORWARD CLUTCH ASSEMBLY

Install the input shaft thrust bearing to the forward clutch.

Standard bearing diameter

BEARING DIAMETER SPECIFICATION

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

Fig 75: Identifying Input Shaft Thrust Bearing

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

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 76: Identifying Forward Clutch
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL OVERDRIVE BRAKE GASKET
1. Install 2 new overdrive brake gaskets to the transaxle.
  
  Fig 77: Identifying Overdrive Brake Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL ASSEMBLY
1. Install the differential assembly to the transaxle.
  
  Fig 78: Identifying Differential Assembly
  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 79: Identifying Thrust Bearing Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL THRUST NEEDLE ROLLER BEARING

Calculate the end play value using the following formula and value of Dimensions D and E that were measured when installing the 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 install it.

Standard end play:

0.498 to 0.993 mm (0.0194 to 0.0390 in.)

Fig 80: 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

RACE THICKNESS SPECIFICATION

E - D	Thickness
Less then 7.34 mm (0.2890 in.)	3.5 mm (0.138 in.)
7.34 mm (0.2890 in.)	3.8 mm (0.150 in.)

Standard bearing and bearing race diameter

BEARING AND BEARING RACE DIAMETER SPECIFICATION

Item	Inside	Outside
Bearing	53.0 mm (2.087 in.)	78.2 mm (3.079 in.)
Bearing race	52.1 mm (2.051 in.)	75.5 mm (2.972 in.)

INSTALL OIL PUMP ASSEMBLY
1. Install the oil pump to the transaxle with the 7 bolts.
  Torque: 22 N*m (226 kgf*cm, 16 ft.*lbf)
  
  Fig 81: Identifying Oil Pump Assembly
  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 82: 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, 09950-70010 (09951-07100, 09951-07100)
  
  NOTE: Do not apply excessive pressure to it.
  
  Fig 83: Identifying Underdrive Cylindrical Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE HOUSING
1. Remove any packing material and be careful not to get oil on the contacting surfaces 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
  
  Fig 84: Identifying Seal Packing Applying Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the transaxle housing and 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.
  
  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
  
  Fig 85: Identifying Transaxle Housing With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Because the bolt A is a seal bolt, apply the 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 86: Identifying No. 1 Transaxle Case Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INPUT SHAFT END PLAY (See INSPECTION )
FIX AUTOMATIC TRANSAXLE ASSEMBLY

Fig 87: Identifying Transaxle On Wooden Blocks
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
1. Coat a new oil seal with ATF, and install it to the transaxle.
2. Install the oil seal to the transaxle.
  
  Fig 88: Identifying Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PARKING LOCK ROD SUB-ASSEMBLY
1. Install the parking lock rod to the manual valve lever.
  
  Fig 89: Identifying Parking Lock Rod
  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 90: Identifying Spacer And Manual Valve Lever Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch and hammer, tap in a new pin.
  
  Fig 91: Identifying Tapping In Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn the spacer and 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.
INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING
1. Using needle-nose pliers, install the retainer spring.
  
  Fig 93: 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 (204 kgf*cm, 15 ft.*lbf)
  
  Bolt length:
  
  25 mm (0.984 in.)
  
  Fig 94: 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, 15 ft.*lbf) for bolt A
  
  12 N*m (122 kgf*cm, 9 ft.*lbf) for bolt B
  
  HINT:
  
  Each bolt length is indicated below.
  
  Bolt length:
  
  27 mm (1.063 in.) for bolt A
  
  16 mm (0.630 in.) for bolt B
  
  Fig 95: 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 96: Identifying B-3 Accumulator Piston O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Coat the accumulator B-3 piston and spring with ATF, and install them to the transaxle.

Standard accumulator spring

ACCUMULATOR SPRING SPECIFICATION

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

Fig 97: Identifying B-3 Piston And Spring

INSTALL C-1 ACCUMULATOR PISTON

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

Fig 98: Identifying C-1 Accumulator Piston O-Rings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Coat the accumulator C-1 piston with ATF, and install it to the transaxle.

Standard accumulator spring

ACCUMULATOR SPRING SPECIFICATION

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

Fig 99: Identifying Accumulator C-1 Piston

INSTALL C-3 ACCUMULATOR PISTON
1. Coat a new O-ring with ATF, and install it to the C-3 accumulator piston.
  
  Fig 100: Identifying C-3 Accumulator Piston O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the C-3 accumulator piston with ATF, and install it to the transaxle.
  
  Fig 101: Identifying C-3 Accumulator Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the compression spring from the C-3 accumulator piston.
  
  Fig 102: Identifying Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CHECK BALL BODY
1. Install the check ball body and spring.
  
  Fig 103: Identifying Check Ball Body And Spring
  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 104: Identifying Transaxle Solenoid Wire 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 105: Identifying Solenoid Wire Retaining Bolt
  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 106: Identifying Brake Drum Gasket
  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 107: Identifying axle 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 108: Identifying No. 1 Governor Apply Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION VALVE BODY ASSEMBLY
1. Make sure that the manual valve lever position, install the valve body with the 17 bolts to the transaxle.
  Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
  
  HINT:
  
  Each bolt length is indicated below.
  
  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
  
  Fig 109: Identifying Valve Body With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Push the valve body against the accumulator piston spring and the check ball body to install it.
  - When installing the valve body to the transaxle case, do not hold the solenoids.
  - Tighten the bolts marked by * in the illustration first temporarily because they are positioning bolts.
2. Connect the 5 solenoid connectors.
3. Install the ATF temperature sensor, clamp and bolt.
  Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf)
  
  Fig 110: Identifying Bolt And Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE BODY OIL STRAINER ASSEMBLY
1. Coat a new O-ring with ATF, and install it to the oil strainer.
  
  Fig 111: Identifying Valve Body Oil Strainer O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the oil strainer and 3 bolts to the valve body.
  Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
  
  Fig 112: Identifying 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 114: Identifying Oil Pan Bolts
  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 to the transaxle.
  Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
  
  Fig 115: Identifying Speed Sensor 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)
  
  Fig 116: Identifying Oil Cooler Inlet Tube Union
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 case.
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
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.
  Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
  
  Fig 118: Identifying No. 1 Transaxle Case Plug With O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BREATHER PLUG HOSE
1. Install the breather plug hose to the breather plug.
INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
1. Install the park/neutral position switch onto the manual valve lever shaft and temporarily install the 2 adjusting bolts.
2. Install a new lock plate and the nut.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
3. Temporarily install the control shaft lever.
  
  Fig 120: Identifying Control Shaft Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Turn the lever counterclockwise until it stops, and then turn it clockwise 2 notches.
5. Remove the control shaft lever.
  
  Fig 121: Identifying Control Shaft Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Align the groove with neutral basic line.
7. Tighten the 2 bolts.
  Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
8. Using a screwdriver, stake the nut with the lock plate.
  
  Fig 123: Identifying Nut With Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Install the control shaft lever, washer and nut.
  Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
  
  Fig 124: Identifying Control Shaft Lever, Washer And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
1. Coat a new O-ring with ATF and install it to the hole cover.
2. Install the hole cover to the transaxle with the bolt.