Reassembly [12/2015 - 08/2016]: Procedure

WARNING: This page is about a different car, the 2016 Toyota Sienna. However, it is still accessible from the selected car via links, so may be relevant.

BEARING POSITION

Check bearing position and installation direction.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Mark	Front Race Diameter Inside / Outside mm (in.)	Thrust Bearing Diameter Inside / Outside mm (in.)	Rear Race Diameter Inside / Outside mm (in.)
A	-	57.9 (2.28) / 75.2 (2.96)	-
B	-	29.3 (1.15) / 48.5 (1.91)	33.1 (1.30) / 48.0 (1.89)
C	-	62.8 (2.47) / 82.2 (3.24)	66.7 (2.63) / 82.1 (3.23)
D	59.7 (2.35) / 76.3 (3.00)	53.1 (2.09) / 78.6 (3.09)	-
E	-	56.1 (2.21) / 80.8 (3.18)	-
F	-	61.4 (2.42) / 78.6 (3.09)	-
G	-	28.0 (1.10) / 46.9 (1.85)	26.3 (1.04) / 44.3 (1.74)
H	51.9 (2.04) / 71.5 (2.81)	49.1 (1.93) / 71.8 (2.83)	-

INSTALL COUNTER DRIVE GEAR BEARING

NOTE:

Perform this procedure only when the counter drive gear bearing or transaxle case is replaced.

Using a snap ring expander, install a new snap ring to a new counter drive gear bearing.

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TEXT IN ILLUSTRATION

*1	Snap Ring
*2	Counter Drive Gear Bearing

Using SST and a press, install the counter drive gear bearing to the transaxle case while compressing the snap ring with a screwdriver.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09950-60020
1. 09951-01030
SST: 09950-70010
1. 09951-07100

NOTE:

Press in the counter drive gear bearing until the snap ring engages with the snap ring groove of the transaxle case.

INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING OUTER RACE

Using SST and a hammer, install a new counter driven gear rear tapered roller bearing outer race to the transaxle case.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09950-60010
1. 09951-00650
SST: 09950-70010
1. 09951-07100

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 transaxle case.

INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING OUTER RACE

Install the shim to the transaxle housing.

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TEXT IN ILLUSTRATION

*1	Counter Driven Gear Front Tapered Roller Bearing Outer Race
*2	Shim

Using SST and a hammer, install a new counter driven gear front tapered roller bearing outer race to the transaxle housing.
- SST: 09950-60020
  1. 09951-00810
- SST: 09950-70010
  1. 09951-07100
NOTE:
Be sure to install the counter driven gear front tapered roller bearing outer race so that there is no clearance between the shim and transaxle housing.

INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING

Using SST and a press, install a new counter driven gear rear tapered roller bearing to the counter driven gear.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09950-60010
1. 09951-00420

NOTE:

Be sure to install the counter driven gear rear tapered roller bearing and differential drive pinion so that there is no clearance between each of them and the counter driven gear.

INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING

Using SST and a press, install a new counter driven gear front tapered roller bearing to the counter driven gear.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09950-60010
1. 09951-00530

NOTE:

Be sure to install the counter driven gear front tapered roller bearing so that there is no clearance between the counter driven gear front tapered roller bearing and counter driven gear.

ADJUST COUNTER DRIVEN GEAR PRELOAD

Remove any remaining seal packing from the contact surfaces of the transaxle housing and transaxle case.

Install the counter driven gear and front differential case to the transaxle case.

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Install the transaxle housing to the transaxle case with the 20 bolts.

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Bolt A

Torque: 31 N*m (312 kgf*cm, 23 ft.*lbf)

Bolt B

Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf)

Using SST and a torque wrench, measure the turning torque of the counter driven gear while rotating SST at 10 rpm.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09564-33010

Turning torque

Differential side bearing preload + 3.48 to 6.48 N*m (36 to 66 kgf*cm, 31 to 57 in.*lbf)

If the turning torque is not within the specified range, refer to the table below to select a shim of the counter driven gear front tapered roller bearing outer race so that the turning torque is within the specified range.

SHIM THICKNESS

Part No.	Thickness mm (in.)
90564-A0142	2.000 (0.0787)
90564-A0143	2.025 (0.0797)
90564-A0144	2.050 (0.0807)
90564-A0145	2.075 (0.0817)
90564-A0146	2.100 (0.0827)
90564-A0147	2.125 (0.0837)
90564-A0148	2.150 (0.0846)
90564-A0149	2.175 (0.0856)
90564-A0150	2.200 (0.0866)
90564-A0151	2.225 (0.0876)
90564-A0152	2.250 (0.0886)
90564-A0153	2.275 (0.0896)
90564-A0154	2.300 (0.0906)
90564-A0155	2.325 (0.0915)
90564-A0156	2.350 (0.0925)
90564-A0157	2.375 (0.0935)
90564-A0158	2.400 (0.0945)
90564-A0159	2.425 (0.0955)
90564-A0160	2.450 (0.0965)
90564-A0161	2.475 (0.0974)
90564-A0162	2.500 (0.0984)
90564-A0163	2.525 (0.0994)
90564-A0164	2.550 (0.100)
90564-A0165	2.575 (0.101)
90564-A0166	2.600 (0.102)
90564-A0167	2.625 (0.103)
90564-A0168	2.650 (0.104)
90564-A0169	2.675 (0.105)
90564-A0170	2.700 (0.106)
90564-A0171	2.725 (0.107)
90564-A0172	2.750 (0.108)
90564-A0173	2.775 (0.109)
90564-A0174	2.800 (0.110)
90564-A0175	2.825 (0.111)
90564-A0176	2.850 (0.112)
90564-A0177	2.875 (0.113)
90564-A0178	2.900 (0.114)
90564-A0179	2.925 (0.115)
90564-A0180	2.950 (0.116)
90564-A0181	2.975 (0.117)
90564-A0182	3.000 (0.118)

Remove the 20 bolts and transaxle housing from the transaxle case.

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Remove the counter driven gear and front differential case from the transaxle case.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

Using SST and a hammer, install a new manual valve lever shaft oil seal to the transaxle case.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09950-60010
1. 09951-00230
SST: 09950-70010
1. 09951-07100

Standard depth

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

NOTE:

Be sure to install the manual valve lever shaft oil seal in the correct direction.

Coat the lip of the manual valve lever shaft oil seal with MP grease.

INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY

Install the manual valve lever shaft sub-assembly to the transaxle case.

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NOTE:

Do not damage the manual valve lever shaft oil seal while installing the manual valve lever shaft sub-assembly to the transaxle case.

Using needle-nose pliers, install the manual valve lever shaft retainer spring to the manual valve lever shaft sub-assembly and transaxle case.

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INSTALL PARKING LOCK ROD SUB-ASSEMBLY

Align the slot with the notches on the manual valve lever shaft sub-assembly and install the parking lock rod sub-assembly to the manual valve lever shaft sub-assembly.

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INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY

Install the manual detent spring sub-assembly and manual detent spring cover to the transaxle case with the bolt.

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Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf)

NOTE:

Make sure to install the manual detent spring sub-assembly first and then the manual detent spring cover.

INSTALL NO. 3 BRAKE PISTON

Coat the lip of the No. 3 brake piston with ATF.

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Temporarily install the pawl stopper plate to the transaxle case with the 2 bolts.

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Install the No. 3 brake piston to the transaxle case.

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TEXT IN ILLUSTRATION

*1	No. 3 Brake Piston
*2	Brake Piston Return Spring

NOTE:

Make sure that the lip of the No. 3 brake piston is not twisted and does not get caught in the transaxle case.
After installation, make sure that the protrusions on the No. 3 brake piston and the grooves on the pawl stopper plate are aligned.

HINT:

Use the installation surface of the brake piston return spring to press the No. 3 brake piston into the transaxle case.

Install the brake piston return spring to the transaxle case.
Remove the 2 bolts and pawl stopper plate from the transaxle case.

Place SST on the brake piston return spring and compress the brake piston return spring using a press.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09387-00070

NOTE:

Stop the press when the brake piston return spring is flush with the snap ring groove. This prevents the brake piston return spring from being deformed.

Using a screwdriver, install the snap ring to the transaxle case.
NOTE:
- Confirm that the snap ring is correctly located in the groove of the transaxle case.
- Be sure to align the opening of the snap ring with one of the protrusions on the brake piston return spring as shown in the illustration.

INSTALL COUNTER DRIVE GEAR

Using SST and a press, install a new bearing inner race (front side) to the counter drive gear.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09387-00020

NOTE:

There should not be any clearance between the bearing inner race (front side) and counter drive gear.

Install 2 new counter drive gear bearings (balls and cage) and counter drive gear to the transaxle case.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST and a press, install a new bearing inner race (rear side) to the counter drive gear.
- SST: 09223-15030
- SST: 09527-1701109950-60020
  1. 09951-00810
- SST: 09950-70010
  1. 09951-07100

INSTALL FRONT PLANETARY GEAR ASSEMBLY

Using SST and a press, install the front planetary gear assembly to the transaxle case.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09223-15030
SST: 09527-17011
SST: 09951-01100

INSTALL NO. 2 BRAKE PISTON

Coat 2 new O-rings with ATF, and install them to the No. 2 brake piston.

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NOTE:

Ensure that the O-rings are not twisted.

Install the No. 2 brake piston to the transaxle case.

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NOTE:

Be careful not to damage the O-rings.

INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

Install the 1st and reverse brake return spring sub-assembly to the transaxle case.

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Place SST on the 1st and reverse brake return spring sub-assembly and compress the 1st and reverse brake return spring sub-assembly using a press.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09387-00060

NOTE:

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

Using a screwdriver, install the snap ring to the transaxle case.
NOTE:
- Confirm that the snap ring is correctly located in the groove of the transaxle case.
- Be sure to align the opening of the snap ring with one of the protrusions on the transaxle case as shown in the illustration.

INSTALL NO. 2 BRAKE DISC

Install the 5 No. 2 brake plates, 5 No. 2 brake discs and No. 2 brake flange to the transaxle case.

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TEXT IN ILLUSTRATION

*1	No. 2 Brake Flange
*2	No. 2 Brake Disc
*3	No. 2 Brake Plate

NOTE:

Make sure that the discs, plates and flange are installed in the correct order.

Using a screwdriver, install the snap ring to the transaxle case.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Confirm that the snap ring is correctly located in the groove of the transaxle case.
Be sure to align the opening of the snap ring with one of the protrusions on the transaxle case as shown in the illustration.

INSPECT CLEARANCE OF NO. 2 BRAKE
See step 15

INSTALL PLANETARY RING GEAR FLANGE

Install the planetary ring gear flange to the planetary ring gear.

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TEXT IN ILLUSTRATION

*1	Snap Ring
*2	Planetary Ring Gear Flange

Using a screwdriver, install the snap ring to the planetary ring gear.
NOTE:
Confirm that the snap ring is correctly located in the groove of the planetary ring gear.

INSTALL PLANETARY RING GEAR

Install the planetary ring gear to the one-way clutch assembly.

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TEXT IN ILLUSTRATION

*1	One-way Clutch Assembly
*2	Planetary Ring Gear

NOTE:

Make sure that the one-way clutch assembly is positioned in the correct direction as shown in the illustration.

INSTALL ONE-WAY CLUTCH ASSEMBLY

Coat the thrust needle roller bearing with ATF, and install it to the front planetary gear assembly.

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BEARING DIAMETER

-	Inside mm (in.)	Outside mm (in.)
Bearing	56.1 (2.21)	80.8 (3.18)

NOTE:

Be sure to install the thrust needle roller bearing in the correct direction.

Install the outer race retainer to the one-way clutch assembly.

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TEXT IN ILLUSTRATION

*1	One-way Clutch Assembly
*2	Outer Race Retainer

Install the one-way clutch assembly to the transaxle case.
NOTE:
Make sure that there is no clearance between the outer race retainer and the claw on the one-way clutch assembly. If there is any clearance, the spring of the outer race retainer will be deformed.

Using a screwdriver, install the snap ring to the transaxle case.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Confirm that the snap ring is correctly located in the groove of the transaxle case.
Be sure to align the opening of the snap ring with one of the protrusions on the transaxle case as shown in the illustration.

INSTALL PARKING LOCK PAWL

Install the parking lock pawl to the transaxle case with the parking lock pawl shaft.

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TEXT IN ILLUSTRATION

*1	Parking Lock Pawl Shaft
*2	Parking Lock Pawl
*3	Spring
*4	Parking Lock Pawl Pin

Install the parking lock pawl pin to the transaxle case.

Install the spring to the parking lock pawl pin.

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NOTE:

Make sure that one end of the spring is set in the hole of the transaxle case and the other end is positioned on the parking lock pawl as shown in the illustration.

INSTALL PARKING LOCK SLEEVE

Install the parking lock sleeve to the transaxle case.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL PAWL STOPPER PLATE

Install the pawl stopper plate to the transaxle case with the 2 bolts.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf)

INSTALL PAWL SHAFT CLAMP

Install the pawl shaft clamp to the transaxle case with the bolt.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf)

INSTALL COUNTER DRIVEN GEAR

Install the counter driven gear to the transaxle case.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL COUNTER DRIVE GEAR NUT

Turn the manual valve lever shaft counterclockwise to set it to the P position as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST, install a new counter drive gear nut to the front planetary gear assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09387-00130

Torque: 120 N*m (1224 kgf*cm, 89 ft.*lbf)

Turn the manual valve lever shaft 2 notches clockwise to set it to the N position as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST and a torque wrench, measure the turning torque of the counter drive gear bearing while rotating SST at 60 rpm.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09387-00130

Turning torque

0.1 to 0.22 N*m (1.1 to 2.2 kgf*cm, 0.9 to 1.9 in.*lbf)

If the measured value is not within the specified range, gradually tighten the counter drive gear nut until the turning torque falls within the specified range.

Maximum torque

180 N*m (1835 kgf*cm, 132 ft.*lbf)

Using a chisel and hammer, stake the front planetary gear assembly.

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INSPECT FRONT DIFFERENTIAL PINION BACKLASH
See step 3

INSTALL FRONT DIFFERENTIAL CASE

Install the front differential case to the transaxle case.

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INSTALL NO. 1 BRAKE PISTON

Coat 2 new O-rings with ATF, and install them to the No. 1 brake piston.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Ensure that the O-rings are not twisted.

Install the No. 1 brake piston to the front oil pump assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Be careful not to damage the O-rings.

INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

Install the 3 2nd brake piston return spring sub-assemblies to the front oil pump assembly.

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NOTE:

Make sure that the 3 2nd brake piston return spring sub-assemblies are installed onto the protrusions on the front oil pump assembly.

INSTALL NO. 1 BRAKE DISC

Install the 4 No. 1 brake plates, 4 No. 1 brake discs and No. 1 brake flange to the front oil pump assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	No. 1 Brake Flange
*2	No. 1 Brake Disc
*3	No. 1 Brake Plate

NOTE:

Make sure that the discs, plates and flange are installed in the correct order.
Be sure to install the flange in the correct direction.

Place SST on the No. 1 brake flange and compress the 2nd brake piston return spring sub-assemblies using a press.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09387-00070
SST: 09495-65040

NOTE:

Stop the press when the 2nd brake piston return spring sub-assemblies are flush with the snap ring groove. This prevents the 2nd brake piston return spring sub-assemblies from being deformed.

Using a screwdriver, install the snap ring to the front oil pump assembly as shown in the illustration.
NOTE:
- Confirm that the snap ring is correctly located in the groove of the front oil pump assembly.
- Make sure to align the protruding part of the snap ring with the indented part (#1) of the front oil pump assembly shown in the illustration to install the snap ring.

Install the brake snap ring stopper to the front oil pump assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Be sure to install the brake snap ring stopper in the correct direction.

Using a screwdriver, install the snap ring to the front oil pump assembly as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Confirm that the snap ring is correctly located in the groove of the front oil pump assembly.
Make sure to align the protruding part of the snap ring with the indented part (#2) of the front oil pump assembly shown in the illustration to install the snap ring.

Check that the brake snap ring stopper can be turned by hand.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Brake Snap Ring Stopper
*2	Snap Ring
*a	Correctly Installed

NOTE:

If the brake snap ring stopper cannot be turned by hand, the brake snap ring stopper may have been installed upside down, or the snap ring may not have been completely located in the groove on the front oil pump assembly. Remove and reinstall the snap rings and brake snap ring stopper.

INSPECT CLEARANCE OF NO. 1 BRAKE
See step 16

INSTALL UNDERDRIVE PLANETARY SUN GEAR

Coat the thrust needle roller bearing with ATF, and install it to the front oil pump assembly.

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TEXT IN ILLUSTRATION

*1	Underdrive Planetary Sun Gear
*2	Thrust Needle Roller Bearing

BEARING DIAMETER

-	Inside mm (in.)	Outside mm (in.)
Bearing	57.9 (2.28)	75.2 (2.96)

NOTE:

Be sure to install the thrust needle roller bearing properly so that the temper colored side of the race will be visible.

Install the underdrive planetary sun gear to the front oil pump assembly.

INSTALL INPUT SHAFT SUB-ASSEMBLY

Coat 3 new input shaft oil seal rings with ATF, and install them to the input shaft sub-assembly.

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TEXT IN ILLUSTRATION

*1	Thrust Needle Roller Race
*2	Thrust Needle Roller Bearing
*3	Input Shaft Oil Seal Ring
*4	Input Shaft Sub-assembly

NOTE:

Do not expand the gap of the input shaft oil seal rings excessively.

Coat the thrust needle roller bearing and thrust needle roller race with ATF, and install them to the input shaft sub-assembly.

BEARING AND RACE DIAMETER

-	Inside mm (in.)	Outside mm (in.)
Bearing	29.3 (1.15)	48.5 (1.91)
Race	33.1 (1.30)	48.0 (1.89)

NOTE:

Be sure to install the thrust needle roller bearing in the correct direction.

Install the input shaft sub-assembly to the front oil pump assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY

Using snap ring pliers, install the snap ring to the underdrive planetary gear assembly.

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TEXT IN ILLUSTRATION

*1	Planetary Sun Gear Sub-assembly
*2	Underdrive Planetary Gear Assembly
*3	Snap Ring

While expanding the snap ring with a snap ring expander, install the planetary sun gear sub-assembly to the underdrive planetary gear assembly.

INSTALL UNDERDRIVE PLANETARY RING GEAR

NOTE:

Perform this procedure only when the underdrive planetary ring gear or No. 3 brake hub is replaced.

Install the snap ring to the underdrive planetary ring gear.

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While compressing the snap ring with a screwdriver, install the underdrive planetary ring gear to the No. 3 brake hub.

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NOTE:

Confirm that the snap ring is correctly located in the groove of the No. 3 brake hub.

INSTALL NO. 3 BRAKE HUB

Coat the thrust needle roller bearing and thrust needle roller race with ATF, and install them to the underdrive planetary gear assembly.

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TEXT IN ILLUSTRATION

*1	Thrust Needle Roller Race
*2	Thrust Needle Roller Bearing

BEARING AND RACE DIAMETER

-	Inside mm (in.)	Outside mm (in.)
Bearing	62.8 (2.47)	82.2 (3.24)
Race	66.7 (2.63)	82.1 (3.23)

NOTE:

Be sure to install the thrust needle roller bearing and thrust needle roller race in the correct direction.

Install the No. 3 brake hub to the underdrive planetary gear assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY

Install the underdrive planetary gear assembly to the front oil pump assembly.

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INSTALL NO. 3 BRAKE DISC

Install the 2 No. 3 brake flanges, 3 No. 3 brake discs and 2 No. 3 brake plates to the front oil pump assembly.

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TEXT IN ILLUSTRATION

*1	No. 3 Brake Flange
*2	No. 3 Brake Disc
*3	No. 3 Brake Plate
*4	No. 3 Brake Flange 3.0 mm (0.118 in.)

NOTE:

Make sure that the discs, plates and flanges are installed in the correct order.

Using a screwdriver, install the snap ring to the front oil pump assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Confirm that the snap ring is correctly located in the groove of the front oil pump assembly.
Make sure that the snap ring ends are positioned as shown in the illustration (A).

INSPECT CLEARANCE OF NO. 3 BRAKE
See step 17

INSTALL FRONT OIL PUMP BODY O-RING

Coat a new front oil pump body O-ring with ATF, and install it to the front oil pump assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Ensure that the O-ring is not twisted.

INSTALL FRONT OIL PUMP ASSEMBLY

Coat a new O-ring with ATF, and install it to the transaxle case.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Thrust Needle Roller Bearing
*2	O-ring

Coat the thrust needle roller bearing with ATF, and install it to the counter drive gear nut.

BEARING DIAMETER

-	Inside mm (in.)	Outside mm (in.)
Bearing	53.1 (2.09)	78.6 (3.09)

NOTE:

Be sure to install the thrust needle roller bearing in the correct direction.

Coat the thrust needle roller race with MP grease, and install it to the underdrive planetary gear assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Thrust Needle Roller Race

RACE DIAMETER

-	Inside mm (in.)	Outside mm (in.)
Race	59.7 (2.35)	76.3 (3.00)

NOTE:

Be sure to install the thrust needle roller race in the correct direction.

Install the front oil pump assembly to the transaxle case with the 7 bolts.

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TEXT IN ILLUSTRATION

*1	Transaxle Case Gasket

Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf)

Coat a new transaxle case gasket with ATF, and install it to the front oil pump assembly.

INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE

Install the differential gear lube apply tube to the transaxle housing.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Insert the differential gear lube apply tube into the transaxle housing until it makes contact with the stopper.

Install the transaxle apply tube clamp to the differential gear lube apply tube with the bolt.
Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf)

NOTE:
There should be clearance between the differential lube apply tube and transaxle apply tube clamp.

INSTALL TRANSAXLE HOUSING

Remove any remaining seal packing from the contact surfaces of the transaxle housing and transaxle case.
NOTE:
Make sure that there is no ATF on the contact surfaces.

Apply a continuous bead of seal packing (width 1.2 mm (0.0472 in.)) to the transaxle case sealing surface as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*a	Seal Packing

Seal packing

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTE:

After applying seal packing, install the transaxle housing to the transaxle case within 3 minutes and tighten the bolts within 10 minutes.

Clean and degrease the 3 bolts B and installation holes in the transaxle case.

Apply adhesive to 2 or 3 threads on the ends of the 3 bolts B.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

Adhesive

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTE:

To prevent contamination by foreign matter, install immediately after applying adhesive.

Install the transaxle housing to the transaxle case with the 20 bolts.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Bolt A

Torque: 31 N*m (312 kgf*cm, 23 ft.*lbf)

Bolt B

Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf)

INSTALL NO. 1 CLUTCH DISC

Install the 4 No. 1 clutch plates, 4 No. 1 clutch discs and No. 1 clutch flange to the direct multiple disc clutch assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	No. 1 Clutch Flange
*2	No. 1 Clutch Disc
*3	No. 1 Clutch Plate

NOTE:

Make sure that the discs, plates and flange are installed in the correct order.

Using a screwdriver, install the 2 snap rings to the direct multiple disc clutch assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Confirm that the snap rings are correctly located in the groove of the direct multiple disc clutch assembly.

INSTALL NO. 2 CLUTCH DISC

Install the No. 2 clutch flange, 3 No. 2 clutch discs and 3 No. 2 clutch plates to the direct multiple disc clutch assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	No. 2 Clutch Plate
*2	No. 2 Clutch Disc
*3	No. 2 Clutch Flange

NOTE:

Make sure that the discs, plates and flange are installed in the correct order.

INSTALL NO. 2 DIRECT CLUTCH PISTON

Install the No. 2 direct clutch piston to the direct multiple disc clutch assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a screwdriver, install the snap ring to the direct multiple disc clutch assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Confirm that the snap ring is correctly located in the groove of the direct multiple disc clutch assembly.

Install the wave spring to the direct multiple disc clutch assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Coat the oil seal lip of the direct clutch piston and direct multiple disc clutch assembly with ATF.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the direct clutch piston to the direct multiple disc clutch assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Be careful not to damage the oil seal lip of the direct clutch piston and direct multiple disc clutch assembly.

Using a screwdriver, install the snap ring to the direct multiple disc clutch assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Confirm that the snap ring is correctly located in the groove of the direct multiple disc clutch assembly.

Install the direct clutch return spring sub-assembly to the direct multiple disc clutch assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the No. 2 clutch balancer to the direct multiple disc clutch assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Place SST on the No. 2 clutch balancer and compress the direct clutch return spring sub-assembly using a press.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09320-89010

NOTE:

Stop the press when the No. 2 clutch balancer is flush with the snap ring groove. This prevents the direct clutch return spring sub-assembly from being deformed.

Using SST, install the snap ring to the direct multiple disc clutch assembly.
- SST: 09350-30020
  1. 09350-07070
NOTE:
Confirm that the snap ring is correctly located in the groove of the direct multiple disc clutch assembly.

INSPECT CLEARANCE OF NO. 1 CLUTCH DISC
See step 18
INSPECT CLEARANCE OF NO. 2 CLUTCH DISC
See step 19

INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

Coat the thrust needle roller race and thrust needle roller bearing with ATF, and install them to the direct multiple disc clutch assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Thrust Needle Roller Bearing
*2	Thrust Needle Roller Race

BEARING AND RACE DIAMETER

-	Inside mm (in.)	Outside mm (in.)
Bearing	28.0 (1.10)	46.9 (1.85)
Race	26.3 (1.04)	44.3 (1.74)

NOTE:

Be sure to install the thrust needle roller bearing properly so that the temper colored side of the race will be visible.

Install the rear planetary sun gear assembly to the direct multiple disc clutch assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a brass bar and a hammer, install the snap ring to the direct multiple disc clutch assembly.

HINT:

Use a piece of cloth to keep the snap ring from flying off.

Coat a new O-ring with ATF, and install it to the direct multiple disc clutch assembly.

TEXT IN ILLUSTRATION

*1	O-ring
*2	Intermediate Shaft Oil Seal Ring

NOTE:

Ensure that the O-ring is not twisted.

Coat a new intermediate shaft oil seal ring with ATF, and install it to the direct multiple disc clutch assembly.
NOTE:
Do not expand the gap of the intermediate shaft oil seal ring excessively.

INSTALL DIRECT MULTIPLE DISC CLUTCH ASSEMBLY

Coat the thrust needle roller bearing with ATF, and install it to the direct multiple disc clutch assembly.

TEXT IN ILLUSTRATION

*1	Direct Multiple Disc Clutch Assembly
*2	Thrust Needle Roller Bearing

BEARING DIAMETER

-	Inside mm (in.)	Outside mm (in.)
Bearing	61.4 (2.42)	78.6 (3.09)

NOTE:

Be sure to install the thrust needle roller bearing in the correct direction.

Install the direct multiple disc clutch assembly to the transaxle case.
NOTE:
Be careful not to damage the O-ring.
Clean the contact surfaces of the transaxle case and transaxle rear cover sub-assembly.

As shown in the illustration, place a straightedge on the direct multiple disc clutch assembly and measure the distance between the transaxle case and straightedge using a vernier caliper (Dimension A).

TEXT IN ILLUSTRATION

*a	Dimension A

As shown in the illustration, place a straightedge on the transaxle rear cover sub-assembly and measure the distance between the transaxle rear cover sub-assembly and straightedge using a vernier caliper (Dimension B).

TEXT IN ILLUSTRATION

*a	Dimension B

Calculate the end play value using the following formula:
End play = Dimension B - Dimension A - Thrust needle roller bearing thickness

Standard end play

0.007 to 1.113 mm (0.000276 to 0.0438 in.)

INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY

Using SST and a hammer, install a new needle roller bearing to the transaxle rear cover sub-assembly.

SST: 09950-60010
1. 09951-00220
SST: 09950-70010
1. 09951-07100

Standard depth

21.5 to 21.9 mm (0.846 to 0862 in.)

Clean and degrease the 2 "TORX" screws and installation holes in the transaxle rear cover sub-assembly.

Apply adhesive to 2 or 3 threads on the ends of the 2 "TORX" screws.

TEXT IN ILLUSTRATION

Adhesive

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTE:

To prevent contamination by foreign matter, install immediately after applying adhesive.

Using a T30 "TORX" socket wrench, install the transaxle rear cover plate to the transaxle rear cover sub-assembly with the 2 "TORX" screws.

Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

Coat 2 new direct clutch drum oil seal rings with ATF, and install them to the transaxle rear cover sub-assembly.

TEXT IN ILLUSTRATION

*1	Direct Clutch Drum Oil Seal Ring

NOTE:

Do not expand the gap of the direct clutch drum oil seal rings excessively.

Coat the thrust needle roller bearing and thrust needle roller race with MP grease, and install them to the transaxle rear cover sub-assembly.

TEXT IN ILLUSTRATION

*1	Thrust Needle Roller Race
*2	Thrust Needle Roller Bearing

BEARING AND RACE DIAMETER

-	Inside mm (in.)	Outside mm (in.)
Bearing	49.1 (1.93)	71.8 (2.83)
Race	51.9 (2.04)	71.5 (2.81)

NOTE:

Be sure to install the thrust needle roller bearing and thrust needle roller race in the correct direction.

Coat 3 new O-rings with ATF, and install them to the transaxle case.

Remove any remaining seal packing from the contact surfaces of the transaxle rear cover sub-assembly and transaxle case.
NOTE:
Make sure that there is no ATF on the contact surfaces.

Apply a continuous bead of seal packing (width 1.2 mm (0.0472 in.)) to the transaxle case sealing surface as shown in the illustration.

TEXT IN ILLUSTRATION

*a	Seal Packing

Seal packing

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTE:

After applying seal packing, install the transaxle housing to the transaxle case within 3 minutes and tighten the bolts within 10 minutes.

Clean and degrease the 2 bolts B and installation holes in the transaxle case.

Apply adhesive to 2 or 3 threads on the ends of the 2 bolts B.

TEXT IN ILLUSTRATION

Adhesive

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTE:

To prevent contamination by foreign matter, install immediately after applying adhesive.

Install the transaxle rear cover sub-assembly to the transaxle case with the 14 bolts.

Bolt A

Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf)

Bolt B

Torque: 17 N*m (172 kgf*cm, 12 ft.*lbf)

Coat 3 new O-rings with ATF, and install them to the 3 transaxle rear cover plugs.

NOTE:

Ensure that the O-rings are not twisted.

Install the 3 transaxle rear cover plugs to the transaxle rear cover sub-assembly.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)

NOTE:
Be careful not to damage the O-rings.

Install a new gasket and refill plug to the transaxle rear cover sub-assembly.

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

INSPECT INPUT SHAFT END PLAY
See step 2

INSTALL TRANSAXLE CASE GASKET

Coat 2 new transaxle case gaskets with ATF, and install them to the transaxle case.

INSTALL TRANSMISSION VALVE BODY ASSEMBLY

Coat the O-ring of the transmission wire with ATF.

Install the transmission valve body assembly to the transaxle case with the 11 bolts.

TEXT IN ILLUSTRATION

*a	Positioning Bolt

Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)

BOLT LENGTH

Bolt	Length mm (in.)
A	25 (0.984)
B	30 (1.18)
C	35 (1.38)
D	45 (1.77)
E	55 (2.17)

NOTE:

When installing the transmission valve body assembly, be careful not to allow the transmission revolution sensor and transaxle case to interfere with each other.
Be sure to insert the pin of the manual valve lever into the groove on the end of the manual valve.
First, temporarily tighten the bolts marked (*a) in the illustration because they are positioning bolts.

INSTALL VALVE BODY OIL STRAINER ASSEMBLY

Coat a new O-ring with ATF, and install it to the valve body oil strainer assembly.

NOTE:

Ensure that the O-ring is not twisted.

Install the valve body oil strainer assembly to the transmission valve body assembly with the 2 bolts.

Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)

NOTE:

Be careful not to damage the O-ring.

INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

Clean and degrease the contact surfaces of the automatic transaxle oil pan sub-assembly and transaxle case.

Install the 2 transmission oil cleaner magnets to the automatic transaxle oil pan sub-assembly.

Clean and degrease the bolt B and installation hole in the transaxle case.

Apply adhesive to 2 or 3 threads on the end of the bolt B.

TEXT IN ILLUSTRATION

Adhesive

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

NOTE:

To prevent contamination by foreign matter, install immediately after applying adhesive.

Install a new automatic transaxle oil pan gasket and automatic transaxle oil pan sub-assembly to the transaxle case with the 18 bolts.

Bolt A

Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

Bolt B

Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)

Using a 6 mm hexagon socket wrench, install the No. 1 transmission oil filler tube to the automatic transaxle oil pan sub-assembly.

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

Using a 6 mm hexagon socket wrench, install a new gasket and overflow plug to the automatic transaxle oil pan sub-assembly.

Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)

INSTALL NO. 2 TRANSAXLE CASE PLUG

Install 3 new gaskets to the 3 No. 2 transaxle case plugs.

Apply adhesive to 2 or 3 threads on the ends of the 3 No. 2 transaxle case plugs.

TEXT IN ILLUSTRATION

Adhesive

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTE:

To prevent contamination by foreign matter, install immediately after applying adhesive.

Using a 6 mm hexagon socket wrench, install the 3 No. 2 transaxle case plugs to the transaxle housing.

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

INSTALL NO. 1 TRANSAXLE CASE PLUG

Coat 3 new O-rings with ATF, and install them to the 3 No. 1 transaxle case plugs.

NOTE:

Ensure that the O-rings are not twisted.

Install the 3 No. 1 transaxle case plugs to the transaxle case.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)

NOTE:
Be careful not to damage the O-rings.

INSTALL OIL COOLER TUBE UNION

Coat 2 new O-rings with ATF, and install them to the 2 oil cooler tube unions.
NOTE:
Ensure that the O-rings are not twisted.

Using a 19 mm deep socket wrench, install the 2 oil cooler tube unions to the transaxle case.

Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)

NOTE:

Be careful not to damage the O-rings.

INSTALL PARK/NEUTRAL POSITION SWITCH

Temporarily install the park/neutral position switch to the transaxle case with the 2 bolts.

NOTE:

Before installing the park/neutral position switch, remove any dirt or rust on the installation portion of the manual valve lever shaft. Be sure to install the switch straight along the shaft while being careful not to deform the plate spring that supports the shaft. If the plate spring is deformed, the park/neutral position switch cannot be reinstalled correctly.

Temporarily install the transmission control shaft lever to the manual valve lever shaft.

Rotate the transmission control shaft lever clockwise until it stops, and then from that position rotate it counterclockwise by 2 notches to set it to the N position.
Remove the transmission control shaft lever from the manual valve lever shaft.

Align the protrusions of the park/neutral position switch.

TEXT IN ILLUSTRATION

*a	Protrusion

Hold the park/neutral position switch in this position and tighten the 2 bolts.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

NOTE:
After installing the park/neutral position switch, confirm that the 2 protrusions on the park/neutral position switch are aligned.

Install the transmission control shaft lever to the manual valve lever shaft with the washer and nut.

Torque: 13 N*m (133 kgf*cm, 9 ft.*lbf)

INSTALL BREATHER PLUG HOSE

Coat a new O-ring with ATF, and install it to the No. 2 breather plug.

TEXT IN ILLUSTRATION

*1	No. 1 Breather Plug
*2	Breather Plug Hose
*3	No. 2 Breather Plug
*4	O-ring

NOTE:

Ensure that the O-ring is not twisted.

Install the No. 1 breather plug and No. 2 breather plug to the breather plug hose.

Install the breather plug hose to the transaxle case.

NOTE:

Be careful not to damage the O-ring.