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Home >> Toyota >> 2019 >> RAV4 XLE, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 71 (Automatic Transaxle System (UB80F) - Service Information (3 Of 3)) >> Automatic Transaxle Unit >> Reassembly [11/2018 - 10/2022] >> Procedure

Reassembly [11/2018 - 10/2022]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. BEARING POSITION 

    Check bearing position and installation direction.

    GTY909139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    GTY744394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Thrust Needle Roller Bearing and Bearing Race Diameter

    FOR AW (AISIN AW) MADE:

    Mark Front Side Thrust Bearing Race Diameter Inside / Outside
    mm (in.)    		 Thrust Bearing Diameter Inside / Outside
    mm (in.)    		 Rear Side Thrust Bearing Race Diameter Inside / Outside
    mm (in.)
    A 29.9 (1.18) / 49.5 (1.95) 28.7 (1.13) / 48 (1.89) 28.7 (1.13) / 48 (1.89)
    B 58.8 (2.31) / 71.4 (2.81) 57.3 (2.26) / 70.94 (2.79) -
    C - 35.2 (1.39) / 49.2 (1.94) 34.3 (1.35) / 46 (1.81)
    D - 37.6 (1.48) / 48.73 (1.92) 38.9 (1.53) / 50.3 (1.98)
    E 32 (1.26) / 43.5 (1.71) 31 (1.22) / 42.5 (1.67) 31 (1.22) / 42.5 (1.67)
    F 23.3 (0.917) / 39.8 (1.57) 22 (0.866) / 40.29 (1.59) 22 (0.866) / 39.8 (1.57)
    G - 47.5 (1.87) / 63.9 (2.52) 49.6 (1.95) / 68.7 (2.70)
    FOR AWNC (AISIN AW) MADE:

    Mark Front Side Thrust Bearing Race Diameter Inside / Outside
    mm (in.)    		 Thrust Bearing Diameter Inside / Outside
    mm (in.)    		 Rear Side Thrust Bearing Race Diameter Inside / Outside
    mm (in.)
    A 30.21 (1.19) / 49.6 (1.95) 28.6 (1.13) / 48.5 (1.91) 28.6 (1.13) / 48.2 (1.90)
    B 58.9 (2.32) / 71.65 (2.82) 57.3 (2.26) / 70.5 (2.78) -
    C - 37 (1.46) / 49.2 (1.94) 34.39 (1.35) / 47.75 (1.88)
    D - 37.6 (1.48) / 48.55 (1.91) 38.9 (1.53) / 50.3 (1.98)
    E 32.1 (1.26) / 43.5 (1.71) 31 (1.22) / 42.1 (1.66) 31 (1.22) / 42.2 (1.66)
    F 23.66 (0.931) / 40.35 (1.59) 21.9 (0.862) / 40.8 (1.61) 21.9 (0.862) / 39.8 (1.57)
    G - 47.5 (1.87) / 63.25 (2.49) 49.15 (1.94) / 64.05 (2.52)
  2. INSTALL AUTOMATIC TRANSMISSION CASE STRAIGHT PIN 
    NOTE:

    It is not necessary to remove the automatic transmission case straight pins unless they are being replaced.

    1. Using a plastic-faced hammer, tap in 2 new automatic transmission case straight pins to the specified protrusion height.
      GTY923462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Protrusion Height

      10.7 to 11.3 mm (0.421 to 0.445 in.)

  3. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (INNER RACE) 

    See step  1

  4. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (OUTER RACE) 

    See step  2

  5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (INNER RACE) 

    See step  3

  6. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (OUTER RACE) 

    See step  4

  7. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING (INNER RACE) 
    1. Using SST and a press, install a new counter driven gear front tapered roller bearing (inner race) to the pinion and counter driven gear sub-assembly.
      GTY754223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09506-35010 
      • SST: 09950-60011 
        1. 09951-00550
      • SST: 09950-70010 
        1. 09951-07150
      NOTE:

      Be sure to install the counter driven gear front tapered roller bearing (inner race) so that there is no clearance between the counter driven gear front tapered roller bearing (inner race) and the pinion and counter driven gear sub-assembly. If there is any clearance, the turning torque of the pinion and counter driven gear sub-assembly cannot be measured correctly.

  8. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING (OUTER RACE) 
    1. Using SST and a hammer, install a new counter driven gear front tapered roller bearing (outer race) and pinion and counter driven gear shim to the transaxle housing.
      GTY754628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60021 
        1. 09951-00720
      • SST: 09950-70010 
        1. 09951-07150
      NOTE:

      Be sure to install the counter driven gear front tapered roller bearing (outer race) so that there is no clearance between the counter driven gear front tapered roller bearing (outer race), pinion and counter driven gear shim and the transaxle housing. If there is any clearance, the turning torque of the pinion and counter driven gear sub-assembly cannot be measured correctly.

  9. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING (INNER RACE) 
    1. Using SST and a press, install a new counter driven gear rear tapered roller bearing (inner race) to the pinion and counter driven gear sub-assembly.
      GTY744846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09506-30012 
      • SST: 09950-60011 
        1. 09951-00420
        2. 09951-00550
      • SST: 09950-70010 
        1. 09951-07150
      NOTE:

      Be sure to install the counter driven gear rear tapered roller bearing (inner race) so that there is no clearance between the counter driven gear rear tapered roller bearing (inner race) and the pinion and counter driven gear sub-assembly. If there is any clearance, the turning torque of the pinion and counter driven gear sub-assembly cannot be measured correctly.

  10. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING (OUTER RACE) 
    1. Using SST and a hammer, install a new counter driven gear rear tapered roller bearing (outer race) to the automatic transaxle case sub-assembly.
      GTY766576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60021 
        1. 09951-00680
      • SST: 09950-70010 
        1. 09951-07150
      NOTE:

      Be sure to install the counter driven gear rear tapered roller bearing (outer race) so that there is no clearance between the counter driven gear rear tapered roller bearing (outer race) and the automatic transaxle case sub-assembly. If there is any clearance, the turning torque of the pinion and counter driven gear sub-assembly cannot be measured correctly.

  11. ADJUST FRONT DIFFERENTIAL CASE TAPERED ROLLER BEARING PRELOAD 
    1. Remove any remaining seal packing from the contact surfaces of the transaxle housing and automatic transaxle case sub-assembly.
    2. Coat the front differential case front tapered roller bearing (inner race) and the front differential case rear tapered roller bearing (inner race) with a sufficient amount of Toyota Genuine ATF WS.
    3. Install the differential case assembly to the automatic transaxle case sub-assembly.
      GTY874604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the transaxle housing to the automatic transaxle case sub-assembly with the 9 bolts (A) and 11 bolts (B).
      GTY890711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 29.4 N.m (300 kgf/cm, 22 ft.lbf) 

      Bolt Length

      Bolt (A) Bolt (B)
      40 mm (1.57 in.) 35 mm (1.38 in.)
    5. Using SST, rotate the differential case assembly 20 times or more to stabilize the bearing.
      • SST: 09564-33010 
      GTY925212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using SST and a torque wrench, measure the turning torque of the front differential case tapered roller bearing while rotating SST at 10 rpm.
      GTY842904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09564-33010 

      Standard Turning Torque

      0.97 to 1.13 N.m (10 to 11 kgf/cm, 9 to 10 in.lbf)

      If the turning torque is not within the specified range, refer to the table below to select a shim so that the turning torque is within the specified range.

      Differential Drive Pinion Shim Thickness

      Part Number Thickness
      mm (in.)      		 Mark
      90564-75002 1.10 (0.0433) 50
      90564-75003 1.13 (0.0445) 51
      90564-75004 1.16 (0.0457) 52
      90564-75005 1.19 (0.0469) 53
      90564-75006 1.22 (0.0480) 54
      90564-75007 1.25 (0.0492) 55
      90564-75008 1.28 (0.0504) 56
      90564-75009 1.31 (0.0516) 57
      90564-75010 1.34 (0.0528) 58
      90564-75011 1.37 (0.0539) 59
      90564-75012 1.40 (0.0551) 60
      90564-75013 1.43 (0.0563) 61
      90564-75014 1.46 (0.0575) 62
      90564-75015 1.49 (0.0587) 63
      90564-75016 1.52 (0.0598) 64
      90564-75017 1.55 (0.0610) 65
      90564-75018 1.58 (0.0622) 66
      90564-75019 1.61 (0.0634) 67
      90564-75023 1.64 (0.0646) 68
      90564-75024 1.67 (0.0657) 69
      90564-75025 1.70 (0.0669) 70
      90564-75026 1.73 (0.0681) 71
      90564-75027 1.76 (0.0693) 72
      90564-75028 1.79 (0.0705) 73
      90564-75029 1.82 (0.0717) 74
      90564-75030 1.85 (0.0728) 75
      90564-75031 1.88 (0.0740) 76
      90564-75032 1.91 (0.0752) 77
      90564-75033 1.94 (0.0764) 78
      90564-75034 1.97 (0.0776) 79
      90564-75035 2.00 (0.0787) 80
    7. Remove the 20 bolts and transaxle housing from the automatic transaxle case sub-assembly.
  12. ADJUST COUNTER DRIVEN GEAR TAPERED ROLLER BEARING PRELOAD 
    1. Coat the counter driven gear front tapered roller bearing (inner race) and the counter driven gear rear tapered roller bearing (inner race) with a sufficient amount of Toyota Genuine ATF WS.
    2. Install the pinion and counter driven gear sub-assembly to the automatic transaxle case sub-assembly.
      GTY874599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the transaxle housing to the automatic transaxle case sub-assembly with the 9 bolts (A) and 11 bolts (B).
      GTY890711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 29.4 N.m (300 kgf/cm, 22 ft.lbf) 

      Bolt Length

      Bolt (A) Bolt (B)
      40 mm (1.57 in.) 35 mm (1.38 in.)
    4. Using SST, rotate the differential case assembly 20 times or more to stabilize the bearing.
      GTY925212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09564-33010 
    5. Using SST and a torque wrench, measure the turning torque of the pinion and counter driven gear tapered roller bearing while rotating SST at 10 rpm.
      GTY842904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09564-33010 

      Standard Turning Torque

      Front differential case tapered roller bearing preload + 0.80 to 1.95 N.m (9 to 19 kgf/cm, 8 to 17 in.lbf)

      If the turning torque is not within the specified range, refer to the table below to select a shim so that the turning torque is within the specified range.

      Pinion and Counter Driven Gear Shim Thickness

      Part Number Thickness
      mm (in.)      		 Mark
      90564-61146 1.18 (0.0465) AA
      90564-61147 1.21 (0.0476) AB
      90564-61127 1.24 (0.0488) AC
      90564-61128 1.27 (0.0500) AD
      90564-61129 1.30 (0.0512) AE
      90564-61130 1.33 (0.0524) AF
      90564-61131 1.36 (0.0535) AG
      90564-61132 1.39 (0.0547) AH
      90564-61133 1.42 (0.0559) AJ
      90564-61134 1.45 (0.0571) AK
      90564-61135 1.48 (0.0583) AL
      90564-61136 1.51 (0.0594) AM
      90564-61137 1.54 (0.0606) AN
      90564-61138 1.57 (0.0618) AP
      90564-61139 1.60 (0.0630) AR
      90564-61140 1.63 (0.0642) AS
      90564-61141 1.66 (0.0654) AT
      90564-61142 1.69 (0.0665) AU
      90564-61143 1.72 (0.0677) AV
      90564-61144 1.75 (0.0689) AW
      90564-61145 1.78 (0.0701) AX
      90564-61148 1.81 (0.0713) AY
      90564-61149 1.84 (0.0724) AZ
      90564-61150 1.87 (0.0736) BA
      90564-61151 1.90 (0.0748) BB
      90564-61152 1.93 (0.0760) BC
      90564-61153 1.96 (0.0772) BD
      90564-61154 1.99 (0.0783) BE
      90564-61155 2.02 (0.0795) BF
      90564-61156 2.05 (0.0807) BG
      90564-61157 2.08 (0.0819) BH
      90564-61158 2.11 (0.0831) BJ
      90564-61159 2.14 (0.0843) BK
      90564-61160 2.17 (0.0854) BL
      90564-61161 2.20 (0.0866) BM
    6. Remove the 20 bolts and transaxle housing from the automatic transaxle case sub-assembly.
    7. Remove the pinion and counter driven gear sub-assembly from the automatic transaxle case sub-assembly.
    8. Remove the differential case assembly from the automatic transaxle case sub-assembly.
  13. INSTALL NO. 2 TRANSAXLE CASE PLUG 
    1. Clean the 6 No. 2 transaxle case plugs and 6 installation holes.
    2. Apply adhesive to 2 or 3 threads on the ends of the No. 2 transaxle case plugs.
      GTY733624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      NOTE:

      Make sure to install the No. 2 transaxle case plugs immediately after applying adhesive to prevent foreign matter from attaching to them.

    3. Using a 6 mm socket hexagon wrench, install the 3 No. 2 transaxle case plugs and 3 new gaskets to the automatic transaxle case sub-assembly.
      GTY764821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 17 N.m (173 kgf/cm, 13 ft.lbf) 

    4. Using a 6 mm socket hexagon wrench, install the 3 No. 2 transaxle case plugs and 3 new gaskets to the transaxle housing.
      GTY764819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 17 N.m (173 kgf/cm, 13 ft.lbf) 

  14. INSTALL NO. 1 TRANSAXLE CASE PLUG 
    1. Coat 8 new O-rings with Toyota Genuine ATF WS and install them to the 8 No. 1 transaxle case plugs.
      GTY698768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 4 No. 1 transaxle case plugs to the automatic transaxle case sub-assembly.
      GTY764815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Install the 4 No. 1 transaxle case plugs to the transaxle housing.
      GTY764820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  15. INSTALL NEEDLE ROLLER BEARING 
    1. Using SST and a press, install a new needle roller bearing to the transaxle housing.
      • SST: 09950-60011 
        1. 09951-00560
      • SST: 09950-70010 
        1. 09951-07200
      GTY761546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the transaxle housing.

  16. INSTALL FRONT DRIVE SHAFT OIL SEAL LH 
    1. Using SST and a hammer, install a new front drive shaft oil seal LH to the automatic transaxle case sub-assembly.
      GTY758221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09649-17010 
      • SST: 09950-70010 
        1. 09951-07200

      Standard Depth

      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

  17. INSTALL TRANSAXLE CASE OIL SEAL 
    1. Clean and degrease the oil seal press-in surface.
    2. Using SST and a hammer, install a new transaxle case oil seal to the transaxle housing.
      GTY852852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60011 
        1. 09951-00640
      • SST: 09950-70010 
        1. 09951-07200

      Standard Depth

      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

    3. Apply MP grease to the lip of the transaxle case oil seal.
  18. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL 
    1. Using SST and a hammer, install a new manual valve lever shaft oil seal to the automatic transaxle case sub-assembly.
      GTY745034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60011 
        1. 09951-00210
      • SST: 09950-70010 
        1. 09951-07200

      Standard Depth

      -0.3 to 0.4 mm (-0.0118 to 0.0157 in.)

    2. Apply MP grease to the lip of the manual valve lever shaft oil seal.
  19. INSTALL 1ST AND REVERSE BRAKE PISTON 
    1. Apply a light coat of Toyota Genuine ATF WS to 2 new O-rings and install them to the 1st and reverse brake piston.
      GTY698783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure to correctly distinguish between the inner side and outer side O-rings.
      • Be careful not to damage or twist the O-rings.
    2. Set the 1st and reverse brake return spring sub-assembly on the 1st and reverse brake piston.
      GTY760811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 1st And Reverse Brake Return Spring Sub-assembly
      *2 1st And Reverse Brake Piston
    3. Install the 1st and reverse brake piston with 1st and reverse brake return spring sub-assembly to the automatic transaxle case sub-assembly.
      GTY744359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure that the O-rings are not damaged or do not jump out of position during installation.

  20. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the 1st and reverse brake return spring sub-assembly and compress it with a press.
      GTY755420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09380-60012 
        1. 09381-06020
        2. 09381-06050
        3. 09381-06070
      • SST: 09950-70010 
        1. 09951-07200
      NOTE:

      Stop the press when the 1st and reverse brake return spring sub-assembly is flush with the snap ring groove.

    2. Using a screwdriver with its tip wrapped with protective tape, set the snap ring on the automatic transaxle case sub-assembly as shown in the illustration.
      GTY758256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Snap ring opening within this area. - -
      NOTE:

      The opening of the snap ring should be within the area shown in the illustration (spline portion).

    3. Using a screwdriver with its tip wrapped with protective tape, install the snap ring into the snap ring groove of the automatic transaxle case sub-assembly.
      NOTE:
      • Be careful not to damage the automatic transaxle case sub-assembly.
      • Make sure that the snap ring is installed in the groove of the automatic transaxle case sub-assembly correctly.
  21. INSTALL NO. 2 1ST AND REVERSE BRAKE PISTON 
    1. Install the No. 2 1st and reverse brake piston to the automatic transaxle case sub-assembly.
      GTY773550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL 2ND BRAKE DISC 
    1. Install the 5 2nd brake plates, 5 2nd brake discs and 2nd brake flange to the automatic transaxle case sub-assembly.
      GTY750132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 2nd Brake Flange
      *2 2nd Brake Disc
      *3 2nd Brake Plate
      *a Snap Ring Side
      *b 2nd Brake Disc Side
      NOTE:

      Assemble the 2nd brake flange with its tapered surface facing toward the 2nd brake disc.

    2. Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the automatic transaxle case sub-assembly.
      GTY743861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Snap ring opening within this area. - -
      NOTE:

      The opening of the snap ring should be within the area shown in the illustration (spline portion).

  23. INSPECT CLEARANCE OF B-2 BRAKE 

    See step  18

  24. INSTALL DIRECT CLUTCH DRUM OIL SEAL RING 
    1. Apply a small amount of MP grease to the entire circumference of the direct clutch drum oil seal ring installation groove portion.

      HINT: 

      By applying MP grease, the wobble within the direct clutch drum oil seal ring installation groove will be eliminated, preventing damage to the direct clutch drum oil seal ring at the time of front planetary gear assembly installation.

    2. Coat 2 new direct clutch drum oil seal rings with Toyota Genuine ATF WS and install them to the automatic transaxle case sub-assembly.
      GTY763297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      While making the spread of the opening of the direct clutch drum oil seal ring as small as possible, install it to the automatic transaxle case sub-assembly. If the ring opening is spread, briefly hold it closed with your fingers to return it to its original condition.

  25. INSTALL C-2 CLUTCH PISTON 
    1. Apply a light coat of Toyota Genuine ATF WS to 2 new O-rings and install them to the intermediate shaft sub-assembly.
      GTY762627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage or twist the O-ring.

    2. Apply a light coat of Toyota Genuine ATF WS to the lip seal of the C-2 clutch piston.
    3. Install the C-2 clutch piston to the intermediate shaft sub-assembly.
      GTY762626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure the lip is not cut or folded.
      • Be careful not to damage the lip seal of the C-2 clutch piston.
  26. INSTALL CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Install the clutch return spring sub-assembly to the intermediate shaft sub-assembly.
      GTY762634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL C-2 CLUTCH BALANCER 
    1. Apply a light coat of Toyota Genuine ATF WS to the lip seal of the C-2 clutch balancer.
    2. Install the C-2 clutch balancer to the intermediate shaft sub-assembly.
      GTY762636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure the lip is not cut or folded.
      • Be careful not to damage the lip seal of the C-2 clutch balancer.
    3. Place SST on the C-2 clutch balancer and compress the clutch return spring sub-assembly with a press.
      GTY757005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09387-00020 
      NOTE:

      Stop the press when the clutch return spring sub-assembly is flush with the snap ring groove.

    4. Using SST, install the snap ring to the intermediate shaft sub-assembly.
      • SST: 09350-30020 
        1. 09350-07070
      NOTE:

      Make sure that the snap ring is installed in the groove of the intermediate shaft sub-assembly correctly.

  28. INSTALL NO. 2 CLUTCH DISC 
    1. Install the 4 No. 2 clutch plates, 4 No. 2 clutch discs and direct clutch flange to the intermediate shaft sub-assembly.
      GTY771480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Direct Clutch Flange
      *2 No. 2 Clutch Disc
      *3 No. 2 Clutch Plate
      *a Snap Ring Side
      *b No. 2 Clutch Disc Side
      NOTE:

      Assemble the direct clutch flange with its tapered surface facing toward the No. 2 clutch disc.

    2. Using a screwdriver with its tip wrapped in protective tape, install the snap ring to the intermediate shaft sub-assembly.
      GTY762637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to damage the intermediate shaft sub-assembly.
      • Make sure that the snap ring is installed in the groove of the intermediate shaft sub-assembly correctly.
  29. INSTALL NO. 1 THRUST BEARING RACE 

    HINT: 

    Refer to introduction and check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

    GTY860517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Serial Number
    Serial Number Factory
    ##6######## for AW (AISIN AW) Made
    ##N######## for AWNC (AISIN AW) Made
    1. Coat the No. 1 thrust bearing race with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.

      No. 1 Thrust Bearing Race Diameter

      FOR AW (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      49.6 (1.95) 68.7 (2.70)
      FOR AWNC (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      49.15 (1.94) 64.05 (2.52)
      NOTE:

      Securely insert the claw of the No. 1 thrust bearing race into the hole of the automatic transaxle case sub-assembly.

      GTY762630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL THRUST NEEDLE ROLLER BEARING 

    HINT: 

    Refer to introduction and check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

    GTY860517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Serial Number
    Serial Number Factory
    ##6######## for AW (AISIN AW) Made
    ##N######## for AWNC (AISIN AW) Made
    1. Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the C-2 clutch assembly.
      GTY762631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Thrust Needle Roller Bearing Diameter

      FOR AW (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      47.5 (1.87) 63.9 (2.52)
      FOR AWNC (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      47.5 (1.87) 63.25 (2.49)
      NOTE:

      Make sure to assemble the thrust needle roller bearing in the correct direction.

  31. INSTALL C-2 CLUTCH ASSEMBLY 
    1. Install the C-2 clutch assembly to the automatic transaxle case sub-assembly.
      GTY762652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      When installing the C-2 clutch assembly, if the thrust needle roller bearing falls off, coat the C-2 clutch assembly installation surface with MP grease and install the parts.

  32. INSPECT CLEARANCE OF C-2 CLUTCH 

    See step  17

  33. INSTALL NO. 2 THRUST BEARING RACE 

    HINT: 

    Refer to introduction and check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

    GTY860517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Serial Number
    Serial Number Factory
    ##6######## for AW (AISIN AW) Made
    ##N######## for AWNC (AISIN AW) Made
    1. Coat the No. 2 thrust bearing race with Toyota Genuine ATF WS and install it to the C-2 clutch assembly.
      GTY762655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      No. 2 Thrust Bearing Race Diameter

      FOR AW (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      22 (0.866) 39.8 (1.57)
      FOR AWNC (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      21.9 (0.862) 39.8 (1.57)
  34. INSTALL THRUST NEEDLE ROLLER BEARING 

    HINT: 

    Refer to introduction and check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

    GTY860517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Serial Number
    Serial Number Factory
    ##6######## for AW (AISIN AW) Made
    ##N######## for AWNC (AISIN AW) Made
    1. Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the C-2 clutch assembly.
      GTY762654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Thrust Needle Roller Bearing Diameter

      FOR AW (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      22 (0.866) 40.29 (1.59)
      FOR AWNC (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      21.9 (0.862) 40.8 (1.61)
  35. INSTALL NO. 4 PLANETARY CARRIER THRUST WASHER 
    1. Install the No. 4 planetary carrier thrust washer to the rear planetary gear assembly.
      GTY740933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Securely insert each protrusion of the No. 4 planetary carrier thrust washer into each indentation of the rear planetary gear assembly.

  36. INSTALL REAR PLANETARY GEAR ASSEMBLY 
    1. Install the rear planetary gear assembly to the C-2 clutch assembly.
      GTY762657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      When installing the rear planetary gear assembly, if the No. 4 planetary carrier thrust washer falls off, coat the rear planetary gear assembly installation surface with MP grease and install the parts.

  37. INSTALL NO. 3 PLANETARY CARRIER THRUST WASHER 
    1. Coat the No. 3 planetary carrier thrust washer with Toyota Genuine ATF WS and install it to the rear planetary gear assembly.
      NOTE:

      Securely insert the claw of the No. 3 planetary carrier thrust washer into the hole of the rear planetary gear assembly.

      GTY762647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL NO. 1 BRAKE DISC 
    1. Install the 4 No. 1 brake plates, 4 No. 1 brake discs and No. 1 brake flange to the counter drive gear sub-assembly.
      GTY747416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Brake Flange
      *2 No. 1 Brake Disc
      *3 No. 1 Brake Plate
      *a Snap Ring Side
      *b No. 1 Brake Disc Side
      NOTE:
      • Be careful during assembly because there are 2 types of No. 1 brake plates with different thicknesses.
      • Assemble the No. 1 brake flange with its tapered surface facing toward the No. 1 brake disc.
    2. Using a screwdriver with its tip wrapped in protective tape, install the snap ring to the counter drive gear sub-assembly.
      GTY769696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Snap ring opening within this area.
      NOTE:
      • Be careful not to damage the counter drive gear sub-assembly.
      • Make sure that the snap ring is installed in the groove of the counter drive gear sub-assembly correctly.
      • The opening of the snap ring should be within the area shown in the illustration (spline portion).
  39. INSTALL COUNTER DRIVE GEAR SUB-ASSEMBLY 
    1. Clean and degrease the counter drive gear sub-assembly installation bolts and the 7 bolt holes.
      NOTE:

      If the bolts are tightened without cleaning and degreasing the bolts and bolt holes, the tightening torque will be too high and the counter drive gear sub-assembly or automatic transaxle case sub-assembly may be damaged.

    2. Coat a new O-ring with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.
      GTY762538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the counter drive gear sub-assembly together with the pinion and counter driven gear sub-assembly to the automatic transaxle case sub-assembly.
      GTY762540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporarily install the 2 "TORX" bolts and 5 bolts.
      GTY743702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      "TORX" Bolt
      Bolt
    5. Tighten the 5 bolts.

      Torque: 76 N.m (775 kgf/cm, 56 ft.lbf) 

    6. Using a T50 "TORX" socket wrench, tighten the 2 "TORX" bolts.

      Torque: 31.8 N.m (324 kgf/cm, 23 ft.lbf) 

  40. INSPECT CLEARANCE OF B-1 BRAKE 

    See step  16

  41. INSTALL PARKING LOCK SLEEVE 
    1. Coat the parking lock sleeve with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.
      GTY762368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL PARKING LOCK PAWL 
    1. Coat the parking lock pawl with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.
      GTY762367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL PARKING LOCK PAWL SHAFT 
    1. Coat the parking lock pawl shaft with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.
      GTY773341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL PARKING LOCK PAWL TORSION SPRING 
    1. Install the parking lock pawl torsion spring to the automatic transaxle case sub-assembly as shown in the illustration.
      GTY762373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Securely insert the parking lock pawl torsion spring all the way into the parking lock pawl shaft.

  45. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY 
    1. Install the manual valve lever shaft sub-assembly to the automatic transaxle case sub-assembly.
      GTY773342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      When installing the manual valve lever shaft sub-assembly, be careful not to damage the manual valve lever shaft oil seal.

  46. INSTALL PARKING LOCK ROD SUB-ASSEMBLY 
    1. Install the parking lock rod sub-assembly as shown in the illustration.
      GTY765704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Manual Valve Lever Shaft Sub-assembly *2 Parking Lock Rod Sub-assembly
      NOTE:

      Securely align the cutouts of the parking lock rod sub-assembly and manual valve lever shaft sub-assembly.

  47. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING 
    1. Install the manual valve lever shaft retainer spring to the automatic transaxle case sub-assembly.
      GTY762377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL PAWL STOPPER PLATE 
    1. Install the pawl stopper plate to the automatic transaxle case sub-assembly with the 2 bolts.
      GTY762376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  49. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY 
    1. Install the manual valve lever sub-assembly to the automatic transaxle case sub-assembly.
      GTY762378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      The pin portion of the manual valve lever shaft sub-assembly must be inserted into the slot of the manual valve lever sub-assembly.

  50. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY 
    1. Coat a new O-ring with Toyota Genuine ATF WS and install it to the manual valve lever shaft sub-assembly.
      GTY698502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Ensure that the O-ring is not twisted.

    2. Align the cutouts of the manual valve lever sub-assembly and manual valve lever shaft sub-assembly, and install the manual valve lever shaft sub-assembly.
      GTY773343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Installing the manual valve lever shaft sub-assembly to the area shown in the illustration will align the cutouts.

    3. Secure the manual valve lever shaft sub-assembly to the automatic transaxle case sub-assembly with the bolt.
      GTY762369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  51. INSTALL FORWARD CLUTCH PISTON 
    1. Using a press and SST, press the new needle roller bearing into the clutch drum sub-assembly to the position shown in the illustration. (for AWNC Made)
      GTY1176946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Needle Roller Bearing - -
      *a Needle Roller Bearing Press Depth - -
      • SST: 09950-60011 
        1. 09951-00310
      • SST: 09950-70010 
        1. 09951-07100

      Needle Roller Bearing Press Depth

      29.5 to 29.9 mm (1.1614 to 1.1772 in.)

      NOTE:
      • If the needle roller bearing is pressed beyond the standard position, replace the needle roller bearing with a new one.
      • Using a press, press with 6860 N (700 kgf, 1542.2 lbf) or less.

      HINT: 

      Only perform this operation when replacing the needle roller bearing or clutch drum sub-assembly.

    2. Apply a light coat of Toyota Genuine ATF WS to a new D-ring and install it to the clutch drum sub-assembly.
      GTY762466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      • Be careful not to damage or twist the D-ring.
      • The rounded surface of the D-ring will be on the outer side of the ring groove.
    3. Apply a light coat of Toyota Genuine ATF WS to a new O-ring and install it to the clutch drum sub-assembly.
      GTY773362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage or twist the O-ring.

    4. Apply a light coat of Toyota Genuine ATF WS to the forward clutch piston and install it to the clutch drum sub-assembly.
      GTY762462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure that the O-ring and D-ring are not damaged or do not jump out of position during installation.
      • Make sure the lip is not cut or folded.
  52. INSTALL REAR CLUTCH PISTON RETURN COMPRESSION SPRING 
    1. Install the rear clutch piston return compression spring to the forward clutch piston.
      GTY762464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure to install in the correct direction.

  53. INSTALL NO. 1 CLUTCH BALANCER 
    1. Apply a light coat of Toyota Genuine ATF WS to the lip seal of the forward clutch piston.
    2. Install the No. 1 clutch balancer to the forward clutch piston.
      GTY762465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the lip seal of the forward clutch piston.

    3. Place SST on the No. 1 clutch balancer and compress the rear clutch piston return compression spring with a press.
      GTY764198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09320-89010 
      NOTE:

      Stop the press when the rear clutch piston return compression spring is flush with the snap ring groove.

    4. Using SST, install the snap ring to the clutch drum sub-assembly.
      • SST: 09350-30020 
        1. 09350-07070
      NOTE:

      Make sure that the snap ring is installed in the groove of the clutch drum sub-assembly correctly.

  54. INSTALL FRONT CLUTCH DISC 
    1. Install the 4 forward multiple disc clutch plates, 4 front clutch discs and forward clutch flange to the clutch drum sub-assembly.
      GTY760856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Forward Clutch Flange
      *2 Front Clutch Disc
      *3 Forward Multiple Disc Clutch Plate
      *a Snap Ring Side
      *b Front Clutch Disc Side
      NOTE:

      Assemble the forward clutch flange with its tapered surface facing toward the front clutch disc.

    2. Using a screwdriver with its tip wrapped in protective tape, install the snap ring to the clutch drum sub-assembly.
      GTY773364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to damage the clutch drum sub-assembly.
      • Make sure that the snap ring is installed in the groove of the clutch drum sub-assembly correctly.
  55. INSTALL TOLERANCE RING 
    1. GTY762468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install a new tolerance ring to the clutch drum sub-assembly.

  56. INSTALL NO. 5 THRUST BEARING RACE 
    1. Coat the No. 5 thrust bearing race with Toyota Genuine ATF WS and install it to the sun gear input hub sub-assembly.
      GTY763136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      No. 5 Thrust Bearing Race Diameter

      Inside
      mm (in.)      		 Outside
      mm (in.)
      38.9 (1.53) 50.3 (1.98)
  57. INSTALL THRUST NEEDLE ROLLER BEARING 

    HINT: 

    Refer to introduction and check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

    GTY860517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Serial Number
    Serial Number Factory
    ##6######## for AW (AISIN AW) Made
    ##N######## for AWNC (AISIN AW) Made
    1. Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the sun gear input hub sub-assembly.
      GTY763145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Thrust Needle Roller Bearing Diameter

      FOR AW (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      37.6 (1.48) 48.73 (1.92)
      FOR AWNC (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      37.6 (1.48) 48.55 (1.91)
  58. INSTALL C-1 CLUTCH ASSEMBLY 
    1. Install the C-1 clutch assembly to the sun gear input hub sub-assembly.
      GTY763146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. INSTALL REAR PLANETARY SUN GEAR SUB-ASSEMBLY 

    HINT: 

    Refer to introduction and check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

    GTY860517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Serial Number
    Serial Number Factory
    ##6######## for AW (AISIN AW) Made
    ##N######## for AWNC (AISIN AW) Made
    1. Coat the thrust bearing race with Toyota Genuine ATF WS and install it to the rear planetary sun gear sub-assembly.
      GTY744809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for AW (AISIN AW) Made *B for AWNC (AISIN AW) Made

      Thrust Bearing Race Diameter

      FOR AW (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      31 (1.22) 42.5 (1.67)
      FOR AWNC (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      31 (1.22) 42.2 (1.66)
    2. Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the rear planetary sun gear sub-assembly.
      GTY773516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Thrust Needle Roller Bearing Diameter

      FOR AW (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      31 (1.22) 42.5 (1.67)
      FOR AWNC (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      31 (1.22) 42.1 (1.66)
    3. Coat the No. 4 thrust bearing race with Toyota Genuine ATF WS and install it to the rear planetary sun gear sub-assembly.
      GTY773514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      No. 4 Thrust Bearing Race Diameter

      FOR AW (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      32 (1.26) 43.5 (1.71)
      FOR AWNC (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      32.1 (1.26) 43.5 (1.71)
    4. Install the planetary sun gear sub-assembly to the rear planetary sun gear sub-assembly.
      GTY763141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST and a press, install the rear planetary sun gear sub-assembly to the C-1 clutch assembly.
      GTY753197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60011 
        1. 09951-00460
      • SST: 09950-70010 
        1. 09951-07100
    6. Coat the No. 3 thrust bearing race with Toyota Genuine ATF WS and install it to the rear planetary sun gear sub-assembly.
      GTY746407Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for AW (AISIN AW) Made *B for AWNC (AISIN AW) Made

      No. 3 Thrust Bearing Race Diameter

      FOR AW (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      23.3 (0.917) 39.8 (1.57)
      FOR AWNC (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      23.66 (0.931) 40.35 (1.59)
  60. INSPECT CLEARANCE OF C-1 CLUTCH 

    See step  15

  61. INSTALL C-1 CLUTCH ASSEMBLY 
    1. Install the C-1 clutch assembly to the counter drive gear sub-assembly.
      GTY754848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      When installing the C-1 clutch assembly, if the No. 3 thrust bearing race falls off, coat the rear planetary sun gear sub-assembly installation surface with MP grease and then install the parts.

  62. INSTALL NO. 6 THRUST BEARING RACE 

    HINT: 

    Refer to introduction and check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

    GTY860517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Serial Number
    Serial Number Factory
    ##6######## for AW (AISIN AW) Made
    ##N######## for AWNC (AISIN AW) Made
    1. Coat the No. 6 thrust bearing race with Toyota Genuine ATF WS and install it to the C-1 clutch assembly.
      GTY771680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      No. 6 Thrust Bearing Race Diameter

      FOR AW (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      34.3 (1.35) 46 (1.81)
      FOR AWNC (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      34.39 (1.35) 47.75 (1.88)
  63. INSTALL THRUST NEEDLE ROLLER BEARING 

    HINT: 

    Refer to introduction and check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

    GTY860517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Serial Number
    Serial Number Factory
    ##6######## for AW (AISIN AW) Made
    ##N######## for AWNC (AISIN AW) Made
    1. Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the C-1 clutch assembly.
      GTY754853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Thrust Needle Roller Bearing Diameter

      FOR AW (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      35.2 (1.39) 49.2 (1.94)
      FOR AWNC (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      37 (1.46) 49.2 (1.94)
  64. INSTALL FRONT PLANETARY RING GEAR 
    1. Install the front planetary ring gear flange to the front planetary ring gear.
      GTY771681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the front planetary ring gear.
      GTY771682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the front planetary ring gear and front planetary ring gear flange.

    3. Install the front planetary ring gear with front planetary ring gear flange to the C-1 clutch assembly.
      GTY754856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. INSTALL REAR INPUT SHAFT OIL SEAL RING 
    1. Apply a small amount of MP grease to the entire circumference of the rear input shaft oil seal ring installation groove portion.
      GTY754855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      By applying MP grease, the wobble within the rear input shaft oil seal ring installation groove will be eliminated, preventing damage to the rear input shaft oil seal ring at the time of front planetary gear assembly installation.

    2. Coat 2 new rear input shaft oil seal rings with Toyota Genuine ATF WS and install them to the front planetary gear assembly.
      NOTE:

      While making the spread of the opening of the rear input shaft oil seal ring as small as possible, install it to the front planetary gear assembly. If the ring opening is spread, briefly hold it closed with your fingers to return it to its original condition.

  66. INSTALL INPUT SHAFT OIL SEAL RING 
    1. Apply a small amount of MP grease to the entire circumference of the input shaft oil seal ring installation groove portion.
      GTY771674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      By applying MP grease, the wobble within the input shaft oil seal ring installation groove will be eliminated, preventing damage to the input shaft oil seal ring at the time of the front oil pump assembly and torque converter assembly installation.

    2. Coat 5 new input shaft oil seal rings with Toyota Genuine ATF WS and install them to the front planetary gear assembly.
      NOTE:

      While making the spread of the opening of the input shaft oil seal ring as small as possible, install it to the front planetary gear assembly. If the ring opening is spread, briefly hold it closed with your fingers to return it to its original condition.

  67. INSTALL NO. 7 THRUST BEARING RACE 

    HINT: 

    Refer to introduction and check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

    GTY860517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Serial Number
    Serial Number Factory
    ##6######## for AW (AISIN AW) Made
    ##N######## for AWNC (AISIN AW) Made
    1. Coat the No. 7 thrust bearing race with Toyota Genuine ATF WS and install it to the front planetary gear assembly.

      No. 7 Thrust Bearing Race Diameter

      FOR AW (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      58.8 (2.31) 71.4 (2.81)
      FOR AWNC (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      58.9 (2.32) 71.65 (2.82)
      NOTE:

      Securely insert the claw of the No. 7 thrust bearing race into the hole of the front planetary gear assembly.

      GTY754821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  68. INSTALL THRUST NEEDLE ROLLER BEARING 

    HINT: 

    Refer to introduction and check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

    GTY860517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Serial Number
    Serial Number Factory
    ##6######## for AW (AISIN AW) Made
    ##N######## for AWNC (AISIN AW) Made
    1. Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the front planetary ring gear.
      GTY754826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Thrust Needle Roller Bearing Diameter

      FOR AW (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      57.3 (2.26) 70.94 (2.79)
      FOR AWNC (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      57.3 (2.26) 70.5 (2.78)
  69. INSTALL FRONT PLANETARY GEAR ASSEMBLY 
    1. Install the front planetary gear assembly to the front planetary ring gear.
      GTY754824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      When installing the front planetary gear assembly, if the No. 7 thrust bearing race falls off, coat the front planetary gear assembly installation surface with MP grease and install the parts.

  70. INSTALL NO. 8 THRUST BEARING RACE 

    HINT: 

    Refer to introduction and check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

    GTY860517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Serial Number
    Serial Number Factory
    ##6######## for AW (AISIN AW) Made
    ##N######## for AWNC (AISIN AW) Made
    1. Coat the No. 8 thrust bearing race with Toyota Genuine ATF WS and install it to the front planetary gear assembly.
      GTY754823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      No. 8 Thrust Bearing Race Diameter

      FOR AW (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      28.7 (1.13) 48 (1.89)
      FOR AWNC (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      28.6 (1.13) 48.2 (1.90)
  71. INSTALL THRUST NEEDLE ROLLER BEARING 

    HINT: 

    Refer to introduction and check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

    GTY860517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Serial Number
    Serial Number Factory
    ##6######## for AW (AISIN AW) Made
    ##N######## for AWNC (AISIN AW) Made
    1. Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the front planetary gear assembly.
      GTY754829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Thrust Needle Roller Bearing Diameter

      FOR AW (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      28.7 (1.13) 48 (1.89)
      FOR AWNC (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      28.6 (1.13) 48.5 (1.91)
  72. INSTALL NO. 9 THRUST BEARING RACE 

    HINT: 

    Refer to introduction and check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

    GTY860517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Serial Number
    Serial Number Factory
    ##6######## for AW (AISIN AW) Made
    ##N######## for AWNC (AISIN AW) Made
    1. Coat the No. 9 thrust bearing race with Toyota Genuine ATF WS and install it to the front planetary gear assembly.
      GTY774677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for AW (AISIN AW) Made *B for AWNC (AISIN AW) Made

      No. 9 Thrust Bearing Race Diameter

      FOR AW (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      29.9 (1.18) 49.5 (1.95)
      FOR AWNC (AISIN AW) MADE:

      Inside
      mm (in.)      		 Outside
      mm (in.)
      30.21 (1.19) 49.6 (1.95)
  73. INSTALL PLANETARY SUN GEAR 
    1. Install the planetary sun gear to the front planetary gear assembly.
      GTY771675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. INSTALL NO. 2 PLANETARY CARRIER THRUST WASHER 
    1. Install the No. 2 planetary carrier thrust washer to the front planetary gear assembly.
      GTY771672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Securely insert each protrusion of the No. 2 planetary carrier thrust washer into each indentation of the front planetary gear assembly.

  75. INSPECT CLEARANCE OF C-4 CLUTCH 

    See step  14

  76. INSPECT CLEARANCE OF C-3 CLUTCH 

    See step  13

  77. INSTALL C-3 AND C-4 CLUTCH ASSEMBLY 
    1. Install the C-3 and C-4 clutch assembly to the front planetary gear assembly.
      GTY771768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. INSTALL PLANETARY CARRIER THRUST WASHER 
    1. Install the planetary carrier thrust washer to the C-3 and C-4 clutch assembly.
      GTY755248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Securely insert the protrusion of the planetary carrier thrust washer into the indentation of the C-3 and C-4 clutch assembly.

  79. INSTALL FRONT OIL PUMP ASSEMBLY 
    1. Install the front oil pump assembly to the automatic transaxle case sub-assembly with the 7 bolts.
      GTY772050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 24.5 N.m (250 kgf/cm, 18 ft.lbf) 

      Bolt Length

      Bolt (A) Bolt (B)
      40 mm (1.57 in.) 30 mm (1.18 in.)
  80. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY 
    1. Install the manual detent spring sub-assembly to the front oil pump assembly with the bolt.
      GTY755426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Manual Detent Spring Sub-assembly
      *2 Manual Valve Lever Shaft Sub-assembly
      *a Correct
      *b Incorrect

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

      NOTE:
      • Securely insert the claw of the manual detent spring sub-assembly into the hole of the front oil pump assembly.
      • Check that the roller portion of the manual detent spring sub-assembly is engaged with the manual valve lever shaft sub-assembly.
  81. INSTALL OIL PUMP SPROCKET REAR THRUST WASHER 
    1. Install the oil pump sprocket rear thrust washer to the front oil pump assembly.
      GTY755243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Securely insert the protrusion of the oil pump sprocket rear thrust washer into the indentation of the front oil pump assembly.

  82. INSTALL TRANSMISSION DRIVE CHAIN 
    1. Using a screwdriver with its tip wrapped in protective tape, align the cutout of the front oil pump drive gear with the position (*a) shown in the illustration.
      GTY732367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Oil Pump Drive Gear
      *a Correct
      *b Incorrect
      *c Protective Tape
      NOTE:

      Do not pry with excessive force when aligning the cutout of the front oil pump drive gear.

    2. Install the transmission drive chain together with the transmission oil pump drive sprocket and oil pump drive shaft sub-assembly to the front oil pump assembly.
      GTY755203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • To avoid damaging the bush of the front oil pump assembly, install the transmission drive chain, transmission oil pump drive sprocket and oil pump drive shaft sub-assembly horizontally relative to the front oil pump assembly.
      • Align the cutout of the oil pump drive shaft sub-assembly and the cutout of the front oil pump drive gear, and install the parts.
  83. INSTALL OIL PUMP SPROCKET FRONT THRUST WASHER 
    1. Install the oil pump sprocket front thrust washer to the transmission oil pump drive sprocket.
      GTY755244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Securely insert the long protrusion of the oil pump sprocket rear thrust washer into the slot of the oil pump sprocket front thrust washer.

  84. INSTALL CLUTCH DRUM OIL SEAL RING 
    1. Apply a small amount of MP grease to the entire circumference of the clutch drum oil seal ring installation groove portion.
      GTY755201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      By applying MP grease, the wobble within the clutch drum oil seal ring installation groove will be eliminated, preventing damage to the clutch drum oil seal ring at the time of torque converter assembly installation.

    2. Coat a new clutch drum oil seal ring with Toyota Genuine ATF WS and install it to the front oil pump assembly.
      NOTE:

      While making the spread of the opening of the clutch drum oil seal ring as small as possible, install it to the front oil pump assembly. If the ring opening is spread, briefly hold it closed with your fingers to return it to its original condition.

  85. INSTALL DIFFERENTIAL CASE ASSEMBLY 
    1. Install the differential case assembly to the automatic transaxle case sub-assembly.
      GTY874605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. INSTALL TRANSMISSION LUBE APPLY TUBE 
    1. Install the transmission lube apply tube to the transaxle housing.
      GTY773496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Correct
      *b Incorrect
      NOTE:

      Insert the transmission lube apply tube until its spool portion is contacting the transaxle housing.

    2. Install the clamp to the transaxle housing with the bolt.
      GTY755192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  87. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE 
    1. Install the differential gear lube apply tube to the transaxle housing.
      GTY774644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Correct
      *b Incorrect
      NOTE:

      Insert the differential gear lube apply tube until its spool portion is contacting the transaxle housing.

  88. INSTALL TRANSMISSION OIL CLEANER MAGNET 
    1. Install the 3 transmission oil cleaner magnets to the transaxle housing oil separator.
      GTY755196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  89. INSTALL TRANSAXLE HOUSING OIL SEPARATOR 
    1. Install the transaxle housing oil separator to the transaxle housing with the 3 bolts.
      GTY755198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  90. INSTALL TRANSAXLE HOUSING 
    NOTE:

    When installing the transaxle housing, check that the transmission drive chain rotates smoothly.

    GTY755241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Peel off the old seal packing from the transaxle housing and automatic transaxle case sub-assembly installation surface, and clean it.
      NOTE:

      Do not damage the installation surface.

    2. Clean the 20 bolts and bolt holes in the automatic transaxle case sub-assembly.
      GTY874598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Clean the inner chamfer of the automatic transaxle case sub-assembly shown in the illustration.
      GTY902700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Area to be cleaned
    4. Apply seal packing to the automatic transaxle case sub-assembly as shown in the illustration.
      GTY874596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal Packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      Standard Seal Diameter

      1.8 mm (0.0709 in.)

      NOTE:

      After applying seal packing, install the transaxle housing within 3 minutes and tighten the bolts within 20 minutes of applying the seal packing.

    5. Coat 5 new transaxle case gaskets with Toyota Genuine ATF WS and install them to the front oil pump assembly.
      GTY934770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Transaxle Case Gasket
      *2 O-ring
    6. Coat a new O-ring with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.
    7. Install the transaxle housing to the automatic transaxle case sub-assembly with the 9 bolts (A) and 11 bolts (B).
      GTY890711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 29.4 N.m (300 kgf/cm, 22 ft.lbf) 

      Bolt Length

      Bolt (A) Bolt (B)
      40 mm (1.57 in.) 35 mm (1.38 in.)
  91. INSTALL DIFFERENTIAL SIDE OIL SEAL 

    Refer to PROCEDURE - Step 6

  92. INSPECT INPUT SHAFT END PLAY 

    See step  12

  93. INSTALL TRANSMISSION REVOLUTION SENSOR (NC) 

    Refer to PROCEDURE - Step 1

  94. INSTALL TRANSMISSION REVOLUTION SENSOR (NT) 

    Refer to PROCEDURE - Step 2

  95. INSTALL TRANSMISSION VALVE BODY ASSEMBLY (w/ Stop And Start System) 

    Refer to PROCEDURE - Step 2

  96. INSTALL TRANSMISSION VALVE BODY ASSEMBLY (w/o Stop And Start System) 

    Refer to PROCEDURE - Step 2

  97. INSTALL TRANSMISSION WIRE (w/ Stop And Start System) 

    Refer to PROCEDURE - Step 1

  98. INSTALL TRANSMISSION WIRE (w/o Stop And Start System) 

    Refer to PROCEDURE - Step 2

  99. INSTALL TRANSMISSION CASE SIDE COVER 

    Refer to PROCEDURE - Step 3

  100. INSTALL NO. 1 BREATHER PLUG (ATM) 
    1. Coat the O-ring portion of the No. 1 breather plug (ATM) with Toyota Genuine ATF WS.
    2. Engage each claw to install a new No. 1 breather plug (ATM) to the automatic transaxle case sub-assembly.
      GTY769674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Indented Portion
      *b Detent
      NOTE:

      Securely push in the No. 1 breather plug (ATM) until the No. 1 breather plug (ATM) is engaged.

      HINT: 

      Install the No. 1 breather plug (ATM) with its detent aligned with the indented portion of the automatic transaxle case sub-assembly.

  101. INSTALL NO. 1 OIL COOLER OUTLET TUBE SUB-ASSEMBLY 
    1. Coat a new O-ring with Toyota Genuine ATF WS and install it to the No. 1 oil cooler outlet tube sub-assembly.
      GTY765012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Ensure that the O-ring is not twisted.

    2. Using a 19 mm union nut wrench, install the No. 1 oil cooler outlet tube sub-assembly to the automatic transaxle case sub-assembly.
      GTY743826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Union Nut Wrench
      *b Torque Wrench Fulcrum Length

      Specified Tightening Torque 

      Torque: 31.1 N.m (317 kgf/cm, 23 ft.lbf) 

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [11/2018 - ]

      • When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)):

        26.7 N.m (272 kgf/cm, 20 ft.lbf)

  102. INSTALL OIL COOLER UNION SUB-ASSEMBLY 
    1. Pass the oil cooler union sub-assembly through 2 new gaskets and temporarily install it to the automatic transaxle case sub-assembly with the oil cooler union bolt.
      GTY769209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Cooler Union Bolt
      *2 Gasket
    2. Temporarily install the oil cooler union sub-assembly bracket portion to the automatic transaxle case sub-assembly with the bolt.
    3. Tighten the oil cooler union bolt.

      Torque: 22.6 N.m (230 kgf/cm, 17 ft.lbf) 

    4. Tighten the bolt.

      Torque: 12 N.m (122 kgf/cm, 9 ft.lbf) 

  103. INSTALL NO. 1 TRANSMISSION OIL FILLER TUBE 
    1. Using a 6 mm socket hexagon wrench, install the No. 1 transmission oil filler tube to the transaxle housing.
      GTY765009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 1.7 N.m (17 kgf/cm, 15 in.lbf) 

  104. INSTALL OVERFLOW PLUG 
    1. Using a 10 mm socket hexagon wrench, install the overflow plug and a new gasket to the transaxle housing.
      GTY770120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 50 N.m (510 kgf/cm, 37 ft.lbf) 

      NOTE:

      To prevent the gasket from being deformed when tightening, coat the gasket with Toyota Genuine ATF WS.

  105. INSTALL REFILL PLUG 
    1. Install the refill plug and a new gasket to the automatic transaxle case sub-assembly.
      GTY773915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 49 N.m (500 kgf/cm, 36 ft.lbf) 

      NOTE:

      To prevent the gasket from being deformed when tightening, coat the gasket with Toyota Genuine ATF WS.

  106. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY 
    1. Temporarily install the park/neutral position switch assembly to the automatic transaxle case sub-assembly with the 2 bolts.
      GTY765019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the transmission control shaft lever to the manual valve lever shaft sub-assembly.
      GTY773917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the transmission control shaft lever clockwise until it stops, then turn it counterclockwise 2 notches.
      GTY754238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a P
      *b N
    4. Remove the transmission control shaft lever from the manual valve lever shaft sub-assembly.
    5. Align the protrusion with the neutral basic line.
      GTY756965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Neutral Basic Line
      *b Protrusion
    6. Hold the park/neutral position switch assembly in that position and tighten the 2 bolts.

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

  107. INSTALL TRANSMISSION CONTROL SHAFT LEVER 
    1. Install the transmission control shaft lever to the manual valve lever shaft sub-assembly with the washer and nut.
      GTY773917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful of the assembly direction of the transmission control shaft lever.

      Torque: 12.7 N.m (130 kgf/cm, 9 ft.lbf) 

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