Automatic Transaxle Unit: Reassembly

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BEARING POSITION

Fig 1: Identifying Bearing Location
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT DIFFERENTIAL CASE TAPERED ROLLER BEARING PRELOAD

Coat the front differential case and bearing with ATF and install them onto the transaxle case.

Fig 2: Identifying Front Differential Case Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the transaxle housing with the 14 bolts.
Torque: Bolt A

29 N*m (300 kgf*cm, 22 ft.*lbf)

Bolt B

22 N*m (225 kgf*cm, 16 ft.*lbf)

Using SST and a small torque wrench, measure the preload of the differential gear.

Preload

TORQUE SPECIFICATION

Bearing	Standard
New	0.98 to 1.57 Nm (10.0 to 16.0 kgfcm 8.7 to 13.9 in.*lbf)
Used	0.49 to 0.78 Nm (5.0 to 8.0 kgfcm 4.3 to 6.9 in.*lbf)

Fig 3: Identifying Preload Of Differential Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the preload is not within the specifications, remove the differential from the transaxle case.

Select a new transaxle case side adjusting shim in accordance with the following table.

Adjusting shim thickness

SHIM THICKNESS SPECIFICATION

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
01	1.90 (0.0748)	11	2.40 (0.0945)
02	1.95(0.0768)	12	2.45 (0.0965)
03	2.00 (0.0787)	13	2.50 (0.0984)
04	2.05 (0.0807)	14	2.55(0.1004)
05	2.10 (0.0827)	15	2.60 (0.1024)
06	2.15 (0.0846)	16	2.65 (0.1043)
07	2.20 (0.0866)	17	2.70 (0.1063)
08	2.25 (0.0885)	18	2.75 (0.1082)
09	2.30 (0.0906)	19	2.80 (0.1102)
10	2.35 (0.0925)

INSTALL TRANSAXLE CASE OIL SEAL
1. Coat the lip of a new oil seal with MP grease.
2. Using SST and a hammer, drive in a new oil seal.
  SST 09554-14010, 09950-70010 (09951 -07100)
  
  Oil seal drive in depth:
  
  1.5 to 2.5 mm (0.059 to 0.098 in.)
  
  Fig 4: Identifying Transaxle Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT TRANSAXLE CASE OIL SEAL
1. Coat the lip of a new oil seal with MP grease.
2. Using SST and a hammer, drive in a new oil seal.
  SST 09726-27012 (09726-02041), 09950-70010 (09951-07150)
  
  Oil seal drive in depth:
  
  5.4 to 6.4 mm (0.213 to 0.252 in.)
  
  Fig 5: Identifying Front Transaxle Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
1. Install transaxle case plate No. 1 onto the transaxle case.
  
  Fig 6: Identifying Transaxle Case Plate No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, install the front drive pinion rear tapered roller bearing onto the transaxle case.
  SST 09950-60010 (09951 -00610), 09950-70010 (09951-07150)
INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
1. Install the thrust bearing onto the transaxle housing.
  
  Fig 7: Identifying Thrust Bearing Onto Transaxle Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install a new front drive pinion front tapered roller bearing onto the transaxle housing.
  SST 09950-60010 (09951 -00650), 09950-70010 (09951-07150)
  
  Fig 8: Identifying Front Drive Pinion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
1. Install the differential gear lube apply tube onto the transaxle housing.
  
  Fig 9: Identifying Differential Gear Lube Apply Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BEARING LOCK PLATE
1. Install the bearing lock plate onto the transaxle housing with the bolt.
  Torque: 11 N*m (115 kgf*cm, 8 ft.*lbf)
  
  Fig 10: Identifying Bolt And Bearing Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COUNTER DRIVE GEAR HOLE SNAP RING
1. Using a screwdriver, install the counter drive gear hole snap ring onto the transaxle case.
  
  Fig 11: Identifying Counter Drive Gear Hole Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COUNTER DRIVE GEAR BEARING
1. Using SST and a hammer, install the counter drive gear bearing LH outer race onto the transaxle case.
  SST 09950-60020 (09951 -00890), 09950-70010 (09951-07150)
  
  Fig 12: Identifying Counter Drive Gear Bearing LH Outer Race Onto Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, install the counter drive gear bearing RH outer race onto the transaxle case.
  SST 09950-60020 (09951 -00890), 09950-70010 (09951-07150)
3. Install the counter drive gear bearing onto the transaxle case.
  
  Fig 13: Identifying Counter Drive Gear Bearing Onto Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
1. Coat the lip of a new oil seal with MP grease.
2. Using SST and a hammer, install a new manual valve lever shaft oil seal.
  SST 09950-60010 (09951 -00220), 09950-70010 (09951-07100)
  
  Oil seal drive in depth:
  
  -0.5 to 0.5 mm (-0.020 to 0.020 in.)
  
  Fig 14: Identifying Manual Valve Lever Shaft Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL DRIVE PINION
1. Using SST and a press, install the differential drive pinion onto the counter driven gear.
  SST 09950-60010 (09951 -00350), 09950-70010 (09951-07150)
  
  NOTE: When replacing the counter driven gear, replace the counter drive gear in the transaxle case as well.
  Press the differential drive pinion in until it comes into contact with the counter driven gear.
  
  Fig 15: Identifying Differential Drive Pinion Onto Counter Driven Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL DRIVE PINION PLUG
1. Using SST and a plastic hammer, install a new differential drive pinion plug onto the differential drive pinion.
  SST 09221 -25026 (09221 -00071)
  
  Standard clearance:
  
  2.5 to 2.6 mm (0.0984 to 0.1023 in.)
  
  Fig 16: Identifying Differential Drive Pinion Plug Onto Differential Drive Pinion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COUNTER DRIVEN GEAR
1. Install the counter driven gear and drive pinion thrust bearing onto the transaxle case.
  
  Fig 17: Identifying Counter Driven Gear And Drive Pinion Thrust Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PARKING LOCK PAWL
1. Coat the parking lock pawl shaft with ATF.
2. Install the parking lock pawl, parking lock pawl shaft torsion spring and parking lock pawl shaft onto the transaxle case.
  NOTE: Check that the parking lock pawl moves smoothly.
  
  Fig 18: Identifying Parking Lock Pawl Torsion Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL VALVE LEVER SHAFT
1. Install the manual valve lever shaft onto the transaxle case.
  NOTE: Do not damage the oil seal lip.
  
  Fig 19: Identifying Manual Valve Lever Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PARKING LOCK ROD SUB-ASSEMBLY
1. Install the parking lock rod onto the manual valve lever.
Fig 20: Identifying Parking Lock Rod
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY
1. Coat the manual valve lever sub-assembly with ATF.
2. Install the manual valve lever and a new manual valve lever spacer onto the manual valve lever shaft.
3. Using a pin punch and hammer, drive in the pin.
  
  Fig 21: Identifying Driving Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. 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.
5. Using a pin punch, stake the spacer through the small hole.
6. Check that the spacer does not turn.
  
  Fig 22: Identifying Staking Spacer Through Small Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING
1. Install the manual valve lever shaft retainer spring onto the manual valve lever shaft.
  
  Fig 23: Identifying Manual Valve Lever Shaft Retainer Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PARKING LOCK PAWL BRACKET
1. Install the parking lock pawl bracket, parking lock rod and cam guide sleeve onto the transaxle case with the 3 bolts.
  Torque: 20 N*m (205 kgf*cm, 15 ft.*lbf)
  
  Fig 24: Identifying Bolts, Cam Guide And Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COUNTER DRIVE GEAR
1. Using SST and a press, install the counter drive gear onto the transaxle case.
  SST 09223-15030, 09527-17011, 09950-60010 (09951-00650), 09950-70010 (09951-07150)
  
  Fig 25: Identifying Counter Drive Gear Onto Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PLANETARY GEAR ASSEMBLY
1. Using SST and a press, install the planetary gear assembly onto the transaxle case.
  SST 09950-60010 (09951 -00480), 09223-15030, 09527-17011, 09950-70010 (09951-07150)
  
  Fig 26: Identifying Planetary Gear Assembly Onto Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COUNTER DRIVE GEAR NUT
1. Fix the counter driven gear with the parking lock pawl.
  
  Fig 27: Identifying Counter Driven Gear With Parking Lock Pawl
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, install a new lock washer and nut.
  SST 09387-00120
  
  Torque: 280 N*m (2,855 kgf*cm, 207 ft.*lbf)
  
  Fig 28: Identifying Lock Washer And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a small torque wrench, measure the rotating torque while turning the counter drive gear at 60 turns per minute.
  SST 09387-00120
  
  Rotating torque:
  
  0.20 to 0.49 N*m (2 to 5 kgf*cm, 2 to 4 in.*lbf)
  
  Fig 29: Identifying Rotating Torque
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST and a hammer, stake the lock nut washer.
  SST 09930-00010
  
  Fig 30: Identifying Staking Lock Nut Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 1ST AND REVERSE BRAKE PISTON O-RING
1. Coat 2 new O-rings with ATF, and install them onto No. 2 brake piston.
  
  Fig 31: Identifying O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 1ST AND REVERSE BRAKE PISTON
1. Coat No. 2 1st and reverse brake piston with ATF, and install it into the transaxle case.
  NOTE: Do not damage the oil seal lip.
  
  Fig 32: Identifying No. 2 1st And Reverse Brake Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
1. Install the 1st and reverse brake return spring subassembly onto the transaxle case.
2. Using SST, a press and a screwdriver, install the snap ring.
  SST 09387-00070
  
  Fig 33: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST AND REVERSE BRAKE DISC
1. Install the 4 plates, 4 discs and flange onto the transaxle case.
2. Using a screwdriver, install the snap ring.

INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE

Using SST and a dial indicator, measure the first and reverse brake clearance while pressing the disc and plate from the rear side.

SST 09350-36010 (09350-06110)

Pack clearance:

0.806 to 1.206 mm (0.0317 to 0.0475 in.)

NOTE: If the clearance is outside the specifications, select a new brake flange.

HINT:

There are 4 different flange thicknesses.

Fig 35: Identifying First And Reverse Brake Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Flange thickness

FLANGE THICKNESS SPECIFICATION

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
-	3.4 (0.134)	2	3.8 (0.150)
1	3.6 (0.142)	3	4.0 (0.157)

Check that the 1st and reverse brake piston moves when compressed air is applied (392 kPa, 4.0 kgf/cm² , 57 psi) to the oil hole.

INSTALL FRONT PLANETARY SUN GEAR
1. Install the planetary sun gear and needle roller bearing onto the planetary gear assembly.
  
  Fig 36: Identifying Planetary Sun Gear And Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTER RACE RETAINER
1. Install the outer retainer onto No. 2 1 -way clutch.
  
  Fig 37: Identifying Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 21-WAY CLUTCH
1. Install the 1-way clutch and 2nd brake piston assembly onto the rear planetary gear assembly.
  
  Fig 38: Identifying 2nd Brake Cylinder And 1-Way Clutch No.2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR PLANETARY GEAR THRUST NEEDLE ROLLER BEARING
1. Install No. 2 thrust bearing race, the planetary gear thrust needle roller bearing and thrust bearing race onto the rear planetary gear assembly.
  
  Fig 39: Identifying No. 2 Thrust Bearing Race, Planetary Gear Thrust Needle Roller Bearing And Thrust Bearing Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR PLANETARY GEAR ASSEMBLY
1. Install the rear planetary gear assembly onto the transaxle case.
2. Using a screwdriver, install the snap ring.
INSPECT NO. 2 1-WAY CLUTCH
1. Check that the rear planetary gear turns freely counterclockwise and locks when turned clockwise.
  
  Fig 41: Identifying No. 2 1-Way Clutch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND BRAKE PISTON SLEEVE
1. Install the 2nd brake piston sleeve onto the transaxle case.
  
  Fig 42: Identifying 2nd Brake Piston Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND BRAKE BRAKE DISC
1. Install the 3 discs, 3 plates and flange onto the transaxle case.
2. Using a screwdriver, install a snap ring onto the transaxle case.

INSPECT PACK CLEARANCE OF 2ND BRAKE

Using a dial indicator, measure the 2nd brake pack clearance while applying and releasing compressed air (392 to 785 kPa, 4 to 8 kgf/cm² , 57 to 114 psi).

Pack clearance:

0.847 to 1.247 mm (0.0333 to 0.0491 in.)

NOTE: If the clearance is outside the specifications, select a new brake flange.

HINT:

There are 4 different flange thicknesses.

Fig 44: Identifying 2nd Brake Pack Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Flange thickness

FLANGE THICKNESS SPECIFICATION

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
-	3.0 (0.118)	2	3.4 (0.134)
1	3.2 (0.126)	3	3.6 (0.142)

INSTALL 2ND COAST AND OVERDRIVE BRAKE FLANGE HOLE SNAP RING
1. Using a screwdriver, install a snap ring onto the transaxle case.
  
  Fig 45: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1-WAY CLUTCH ASSEMBLY
1. Install No. 2 thrust washer onto the rear planetary gear assembly.
2. Install 1-way clutch assembly onto the rear planetary sun gear assembly.
  
  Fig 46: Identifying 1-Way Clutch Assembly And Planetary Carrier Thrust Washer No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 1-WAY CLUTCH ASSEMBLY
1. Hold the rear planetary sun gear and turn the 1-way clutch and check that the 1-way clutch turns freely counterclockwise and locks when turned clockwise.
  
  Fig 47: Identifying 1-Way Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING
1. Install the thrust bearing and a washer onto the rear planetary sun gear.
  
  Fig 48: Identifying Thrust Bearing And Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR PLANETARY SUN GEAR ASSEMBLY
1. Install the rear planetary sun gear assembly.
  
  Fig 49: Identifying Rear Planetary Sun Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR NO. 2 PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING
1. Install the thrust bearing onto the rear planetary sun gear.
  
  Fig 50: Identifying Thrust Bearing And Rear Planetary Sun Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT CLUTCH HUB
1. Install the direct clutch hub.
  
  Fig 51: Identifying Direct Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL THRUST NEEDLE ROLLER BEARING
1. Install No. 3 thrust bearing race, the thrust needle roller bearing and the C-2 hub thrust bearing race onto the direct clutch hub.
  
  Fig 52: Identifying No. 3 Thrust Bearing Race, Thrust Needle Roller Bearing And C-2 Hub Thrust Bearing Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND COAST AND OVERDRIVE BRAKE DISC
1. Install the 2 discs, 2 plates and flange onto the transaxle case.
  
  Fig 53: Identifying Discs, Plates And Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTERMEDIATE SHAFT ASSEMBLY
1. Install the intermediate shaft assembly onto the transaxle case.
  
  Fig 54: Identifying Intermediate Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 2ND COAST AND OVERDRIVE BRAKE CLEARANCE

As shown in the illustration, place a straight edge on the transaxle case and measure the distance between the 2nd coast and O/D brake flange and straight edge using vernier calipers. (Dimension A)

Fig 55: Identifying 2nd Coast And Overdrive Brake Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

As shown in the illustration, place a straight edge on the O/D brake piston and measure the distance between the transaxle rear cover and straight edge using vernier calipers. (Dimension B)

Calculate the piston stroke value using the following formula. Select a flange which meets the piston stroke value and install it.

Pack clearance:

2.091 to 2.491 mm (0.0823 to 0.0981 in.)

NOTE: If the clearance is outside the specifications, select a new brake flange.

HINT:

There are 4 different flange thicknesses.

Fig 56: Identifying Distance Between Transaxle Rear Cover And Straight Edge

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Flange thickness

FLANGE THICKNESS SPECIFICATION

Mark	Thickness mm (in.)	Mark	Thickness mm (in,)
4	4.0 (0.1575)	6	4.4 (0.1732)
5	4.2 (0.1654)	7	4.6 (0.1811)

INSTALL REAR CLUTCH DRUM THRUST NEEDLE ROLLER BEARING
1. Install the bearing onto the intermediate shaft.
  
  Fig 57: Identifying Bearing And Intermediate Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INTERMEDIATE SHAFT ASSEMBLY
1. Install the transaxle rear cover with the 11 bolts.
  Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
  
  Fig 58: Identifying Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a dial indicator, measure the clearance of the intermediate shaft.
  Standard clearance:
  
  0.204 to 0.966 mm (0.008 to 0.038 in.)
  
  Fig 59: Identifying Clearance Of Intermediate Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 11 bolts and the transaxle rear cover.
INSTALL TRANSAXLE CASE GASKET
1. Install 4 new gaskets onto the transaxle case.
  
  Fig 60: Identifying Transaxle Case Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR TRANSAXLE COVER ASSEMBLY
1. Apply FIPG to the transaxle case.
  FIPG:
  
  Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
  
  Fig 61: Identifying FIPG To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rear transaxle cover with the 11 bolts.
  Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
  
  Fig 62: Identifying Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY
1. Install the forward clutch hub sub-assembly onto the transaxle case.
  
  Fig 63: Identifying Forward Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD CLUTCH HUB THRUST NEEDLE ROLLER BEARING
1. Install the bearing onto the forward clutch hub.
  
  Fig 64: Identifying Bearing And Forward Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STATOR SHAFT THRUST NEEDLE ROLLER BEARING
1. Install the bearing onto the input shaft assembly.
  
  Fig 65: Identifying Bearing And Input Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INPUT SHAFT ASSEMBLY
1. Install the input shaft assembly onto the transaxle case.
  
  Fig 66: Identifying Input Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OVERDRIVE BRAKE GASKET
1. Install 2 new gaskets onto the transaxle case.
  
  Fig 67: Identifying Overdrive Brake Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL GEAR ASSEMBLY
1. Install the differential gear assembly onto the transaxle case.
  
  Fig 68: Identifying Differential Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL PUMP ASSEMBLY
1. Install the oil pump with the 7 bolts.
  Torque: 22 N*m (225 kgf*cm, 16 ft.*lbf)
  
  Fig 69: Identifying Bolts And Oil Pump Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INPUT SHAFT ASSEMBLY
1. Make sure that the input shaft turns smoothly.
  
  Fig 70: Identifying Input Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INPUT SHAFT END PLAY
1. Measure the end play in the axial direction.
  End play:
  
  0.37 to 1.29 mm (0.0146 to 0.0508 in.)
  
  If the end play is not as specified, replace the thrust needle roller bearing.
  
  Fig 71: Identifying Input Shaft End Play
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE HOUSING
1. Apply FIPG to the transaxle case.
  FIPG:
  
  Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
  
  Fig 72: Identifying FIPG To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the transaxle housing with the 14 bolts.
  Torque: Bolt A
  
  29 N*m (300 kgf*cm, 22 ft.*lbf)
  
  Bolt B
  
  22 N*m (225 kgf*cm, 16 ft.*lbf)
  
  Fig 73: Identifying Transaxle Housing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL C-2 ACCUMULATOR PISTON

Coat 2 new O-rings with ATF and install them onto the C-2 accumulator piston.
NOTE: Do not damage the O-rings.

Fig 74: Identifying O-Rings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the spring and C-2 accumulator piston.

Accumulator spring

ACCUMULATOR SPRING LENGTH DIAMETER

Spring	Free length/ Outer diameter mm (in.)	Color
C-2	66.90 (2.6339) 17.20 (0.6772)	-

Fig 75: Identifying Spring And C-2 Accumulator Piston

INSTALL C-3 ACCUMULATOR PISTON

Coat 2 new O-rings with ATF and install them onto the C-3 accumulator piston.
NOTE: Do not damage the O-rings.

Fig 76: Identifying O-Rings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the spring and C-3 accumulator piston.

Accumulator spring

ACCUMULATOR SPRING LENGTH DIAMETER

Spring	Free length/ Outer diameter mm (in.)	Color
C-3	80.20 (3.1575) 18.70 (0.7362)	Blue

Fig 77: Identifying Spring And C-3 Accumulator Piston

INSTALL B-2 ACCUMULATOR PISTON

Coat 2 new O-rings with ATF and install them onto the B-2 accumulator piston.
NOTE: Do not damage the O-rings.

Fig 78: Identifying O-Rings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the spring and B-2 accumulator piston.

Accumulator spring

ACCUMULATOR SPRING LENGTH DIAMETER

Spring	Free length/ Outer diameter mm (in.)	Color
B-2	66.90 (2.6339) 15.50 (0.6102)	Green

Fig 79: Identifying Spring And B-2 Accumulator Piston

INSTALL CHECK BALL BODY
1. Install the spring and check ball body.
  
  Fig 80: Identifying Spring And Check Ball Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE DRUM GASKET
1. Install a new brake drum gasket.
  
  Fig 81: Identifying Brake Drum Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE CASE GASKET
1. Coat a new transaxle case gasket with ATF, and install it onto the transaxle case.
  
  Fig 82: Identifying Transaxle Case 2nd Brake 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 onto the transaxle case.
  
  Fig 83: Identifying Transaxle Case 2nd Brake Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION WIRE
1. Coat a new O-ring with ATF, and install it onto the transmission wire.
  
  Fig 84: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Insert the transmission wire into the transaxle.
  
  Fig 85: Identifying Transmission Wire Through Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the transmission wire with the bolt.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  Fig 86: Identifying Bolt And Transmission Wire
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION VALVE BODY ASSEMBLY
1. Align the groove of the manual valve with the pin of the manual valve lever.
2. Provisionally install the valve body with the 13 bolts.
  Bolt length:
  
  Bolt A: 32 mm (1.26 in.)
  
  Bolt B: 22 mm (0.87 in.)
  
  Bolt C: 55 mm (2.17 in.)
  
  Bolt D: 45 mm (1.77 in.)
  
  Fig 87: Identifying Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Provisionally install the detent spring and detent spring cover with the 2 bolts.
  Bolt length:
  
  Bolt A: 14 mm (0.55 in.)
  
  Bolt B: 45 mm (1.77 in.)
  
  Fig 88: Identifying Detent Spring, Detent Spring Cover And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check that the manual valve lever is in contact with the center of the roller at the tip of the detent spring.
5. Tighten the 15 bolts.
  Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)
6. Connect the 5 solenoid connectors.
7. Install the ATF temperature sensor with the lock plate and bolt.
  Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)
  
  Bolt length:
  
  55 mm (2.17 in.)
  
  Fig 89: 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 into the oil strainer.
  
  Fig 90: Identifying Oil Strainer Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the valve body oil strainer assembly onto the automatic transaxle with the 3 bolts.
  Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)
  
  Fig 91: Identifying Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY
1. Install the 2 magnets onto the oil pan.
2. Install a new oil pan gasket onto the oil pan.
3. Install the oil pan with the 19 bolts.
  Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
  
  Fig 93: Identifying Oil Pan Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BREATHER PLUG HOSE
1. Install the breather plug hose onto the transaxle case.
  
  Fig 94: Identifying Breather Plug Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 TRANSAXLE CASE PLUG
1. Coat 5 new O-rings with ATF, and install them onto the screw plugs.
2. Install the 4 screw plugs onto the transaxle housing and transaxle case.
  Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
  
  Fig 95: Identifying No. 1 Transaxle Case Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the screw plug onto the transaxle case.
  Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
  
  Fig 96: Identifying No. 1 Transaxle Case Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL COOLER TUBE UNION
1. Coat 2 new O-rings with ATF, and install them into the 2 oil cooler tube unions.
2. Install the 2 oil cooler tube unions onto the transaxle case.
  Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
INSTALL TRANSMISSION REVOLUTION SENSOR
1. Coat a new O-ring with ATF, and install it into the transmission revolution sensor.
2. Install the transmission revolution sensor onto the transaxle case with the bolt.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  Fig 98: Identifying Bolt And Transmission Revolution Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
1. Install the park/neutral position switch assembly onto the manual transaxle.
2. Provisionally install the 2 bolts.
3. Replace the lock plate with a new one and tighten the manual valve shaft nut.
  Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
4. Provisionally install the control shaft lever.
5. Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches.
6. Remove the control shaft lever.
7. Align the groove with the neutral basic line.
8. Hold the switch in this position and tighten the 2 bolts.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
9. Using a screwdriver, stake the nut with the lock plate.
  
  Fig 102: Identifying Staking Nut With Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Install the control shaft lever with the nut and washer.
  Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
  
  Fig 103: Identifying Control Shaft Lever With Nut And Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPEEDOMETER DRIVEN GEAR
1. Coat a new O-ring with ATF and install it into the speedometer sensor.
2. Install the driven gear into the speedometer sensor with the clip.
INSTALL SPEEDOMETER SENSOR
1. Install the speedometer sensor onto the transaxle housing.
  
  Fig 105: Identifying Bolt And Speedometer Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002