Part 1

U241E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY

1. BEARING POSITION

Standard bearing position:

2. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE

(a) Install the apply tube and apply tube clamp to the transaxle housing with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)
NOTE: Make sure to insert the tube to the stopper.

3. INSTALL NO. 2 BREATHER PLUG
4. INSTALL COUNTER DRIVE GEAR HOLE SNAP RING

(a) Using a screwdriver, install the hole snap ring to the transaxle.
5. INSTALL COUNTER DRIVE GEAR

(a) Using SST and a press, press in the 2 counter drive gear bearings outer races to the transaxle.
- Press-fit the bearing race until it contacts the snap ring.
- Do not apply excessive pressure.

SST: 09950-60020
09951-00890
09951-07150

(b) Using SST and a press, press in the tapered roller bearing to the counter drive gear.
SST: 09649-17010
- Press-fit the bearing inner race until it contacts the counter drive gear.
- Do not apply excessive pressure.

(c) Using SST and a press, press in the counter drive gear and bearing to the transaxle.
SST: 09950-60020
09951-00890
SST: 09950-70010
09951-07150
NOTE: Do not apply excessive pressure.

6. INSTALL 1ST AND REVERSE BRAKE PISTON

(a) Coat 2 new O-rings with ATF.
(b) Install the 2 O-ring to the 1st and reverse brake piston.

(d) Install the 1st and reverse brake return spring to the 1st and reverse brake piston.

(e) Using SST, a press and snap ring expander, press the piston return spring and snap ring to the transaxle.
- Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, preventing the spring sheet from being deform.
- Do not expand the snap ring excessively.

7. INSTALL FRONT PLANETARY RING GEAR

(a) Using a screwdriver, install the front planetary ring gear and brake hub snap ring to the brake hub.
8. INSTALL FRONT PLANETARY GEAR ASSEMBLY

(a) Install the front planetary gear to the brake hub.

(b) Using SST and a press, press-fit the front planetary gear.
NOTE: Do not apply excessive pressure to it.

(d) Using SST, install the nut.
SST: 09387-00030
SST: 09387-00080
Torque: 280 Nm (2,855 kgf-cm, 206 ft-lbf)

(e) Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm. When the measured value is not within the specified value, gradually tighten the nut until it reaches the specified value.
SST: 09950-60010
09951-00400
SST: 09950-70010
09951-07100
SST: 09387-00030
SST: 09387-00080
Turning torque at 60 rpm - Torque: 0.5 to 1.0 Nm (5.1 to 10.0 kgf-cm, 4.4 to 8.7 in-lbf)
Turning torque at 60 rpm - Torque: 0.3 to 0.5 Nm (3.1 to 5.1 kgf-cm, 2.7 to 4.4 in-lbf)

(f) Using a chisel and hammer, stake the front planetary gear washer.
9. INSTALL INPUT SUN GEAR

(a) Install the 2 thrust bearings, bearing race and front planetary sun gear to the planetary gear.
Standard bearing race diameter:

10. INSTALL REAR PLANETARY GEAR ASSEMBLY

(a) Coat the bearing race with ATF, and install it to the rear planetary gear.
Standard bearing race diameter:

(b) Install the planetary carrier thrust washer to the planetary gear.

(d) Using a screwdriver, install the snap ring to the brake hub.
11. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC

(a) Install the 5 plates and 5 discs.
Install in order:
P - D - P - D - P - D - P - D - P - D
HINT: P = Plate
D = Disc

(b) Using a vernier caliper, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle (Dimension A).
(c) Select an appropriate flange so that the piston stroke will meet the specified value.
Pack clearance:
1.02 to 1.21 mm (0.0402 to 0.0476 in.)
HINT: Piston stroke = Dimension A - Flange thickness

Standard flange thickness:

(d) Install the flange.
12. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE
13. INSTALL 1-WAY CLUTCH SLEEVE OUTER

(a) Install the 1-way clutch outer sleeve to the 2nd brake cylinder.
NOTE: Check the positioning direction of the outer sleeve.

14. INSTALL 1-WAY CLUTCH ASSEMBLY

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

(b) Check the rotating direction of the 1-way clutch for the lock or free operation, as shown in illustration.

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

15. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

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

(b) Coat the bearing with petroleum jelly, and install it onto the rear planetary sun gear.
Standard bearing diameter:

(a) Install the 3 discs and 3 plates to the transaxle.
Install in order:
P - D - P - D - P - D
HINT: P = Plate
D = Disc

(b) Temporarily install the snap ring.

(c) Using a vernier caliper, measure the distance between the disc surface and snap ring surface.
(d) Select an appropriate flange so that the piston stroke will meet the specified value.
Standard pack clearance:
0.62 to 0.91 mm (0.0244 to 0.0358 in.)
HINT: Piston stroke = Clearance - Flange thickness -Snap ring thickness 1.6 mm (0.063 in.)

Standard flange thickness:

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

17. INSTALL DIRECT CLUTCH

(a) Install the bearing race to the direct clutch.
Standard bearing diameter:

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

(c) Clean the connector part of the transaxle case and rear cover.
(d) As shown in the illustration, place a straightedge on the direct clutch drum and measure the distance between the transaxle case and the straightedge using a vernier caliper (Dimension B).

(e) Measure the 2 places of the rear cover as shown in the illustration and calculate a dimension C using the following formula.
HINT: Dimension C = Dimension (1) - Dimension (2)

(f) Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install it.
End play:
0.198 to 0.936 mm (0.00800 to 0.03685 in.)
NOTE: Make sure that the colored race side is facing the direct clutch assembly.
HINT: End play = Dimension C - Dimension B

Standard bearing thickness and diameter:

18. INSTALL NO. 1 GOVERNOR APPLY GASKET

(a) Install 2 new apply gaskets to the transaxle.
19. INSTALL FRONT CLUTCH APPLY TUBE

(a) Install the clamp to the front clutch apply tube.
NOTE: Make sure to install the clamp to the apply pipe before installing the apply pipe to the transaxle case. This prevents the apply pipe from being deformed or damaged.

20. INSTALL BRAKE APPLY TUBE

(a) Install the clamp to the brake apply tube.
NOTE: Make sure to install the clamp to the apply pipe before installing the apply pipe to the transaxle case. This prevents the apply pipe from being deformed or damaged.

(b) Install the 2 apply tubes to the transaxle with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
NOTE: Each pipe should be securely inserted until it reaches the stopper.

21. INSTALL NO. 1 TRANSAXLE CASE PLUG

(a) Install 2 new O-rings to the 2 plugs.
(b) Install the 2 plugs to the transaxle rear cover.
Torque: 7.4 Nm (75 kgf-cm, 65 in-lbf)
22. INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY

(a) Using SST and a press, press in the bearing.
SST: 09950-60010
09951-00230
09951-00350
Standard depth:
12.05 to 12.75 mm (0.4744 to 0.5020 in.)
- Face the inscribed mark side of the bearing race up.
- Repeat the press-fit until the specified value is obtained.

(b) Apply adhesive to the 2 screws.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(c) Using a T30 ''TORX'' socket, install the transaxle rear cover plate with the 2 screws.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)

(d) Coat 2 new oil seal rings with ATF, and install them to the transaxle rear cover.

(e) Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover or the transaxle.
(f) Apply seal packing to the cover.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
(g) Coat the needle roller bearing with ATF.

(h) Apply adhesive to the threads of the bolts labeled A.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(i) Install the 11 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf) for bolt A
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf) for other bolt
23. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING

(a) Install 2 new oil seals to the transaxle.
24. INSTALL UNDERDRIVE BRAKE PISTON

(a) Wind a vinyl tape around SST at the 4.0 mm (0.157 in.) above from the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 in.).
SST: 09550-60010
09951-00320
NOTE: Clean SST to remove deposited oil before winding a vinyl tape.

(b) Using SST and a press, press in the needle-roller bearing to the transaxle until the wound vinyl tape contacts the transaxle case.
SST: 09550-60010
09951-00320
SST: 09950-70010
09951-07100
SST: 09387-00020

(d) Install the underdrive brake piston to the transaxle.
25. INSTALL UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY

(a) Install the underdrive brake return spring to the underdrive brake piston.

(b) Using SST, a snap ring expander and press, press the return spring and install the snap ring to the transaxle.
SST: 09387-00020
NOTE: Do not apply excessive pressure.

26. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC

(a) Install the 3 discs and 3 plates to the transaxle.
Install in order:
P - D - P - D - P - D
HINT: D = Disc
P = Plate

(b) Using a screwdriver, install the snap ring.

(c) Using a dial indicator, measure the underdrive brake piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Standard piston stroke:
1.81 to 2.20 mm (0.0713 to 0.0866 in.)
HINT: Select an appropriate flange from the table below so that it will meet the specified value.

Standard flange thickness:

(d) Temporarily remove the snap ring and attach the flange. Restore the snap ring.