Part 2

U241E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY - Continued

27. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY

(a) Install the outer race retainer to the 1-way clutch.

(b) Install the underdrive clutch assembly to the 1-way clutch. Rotate the underdrive clutch to check the rotating direction for the lock or free operation.

(c) Install the 1-way clutch to the transaxle.
NOTE: Make sure that the mark on the 1-way clutch outer race is visible.

(d) Using a screwdriver, install the snap ring to the transaxle.

28. INSTALL UNDERDRIVE CLUTCH

(a) Coat the bearing and bearing race with petroleum jelly, and install them onto the underdrive clutch.
Standard race diameter:

(b) Install the underdrive clutch assembly to the transaxle.
29. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY

(a) Install the parking lock pawl pin and torsion spring to the parking lock pawl.

(b) Temporarily install the parking lock pawl, shaft and spring to the transaxle case as shown in the illustration.

(c) Install the underdrive planetary gear assembly to the transaxle.
NOTE: Engage all the discs of the underdrive clutch and hub splines of the underdrive planetary gear assembly firmly and assemble them securely.

(d) Install the parking lock pawl shaft.

(e) Install the pawl shaft clamp with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)

(f) Using a straightedge and vernier caliper as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and contact surface of the transaxle and housing (Dimension D).
NOTE: Note down the dimension D as it is necessary for the following process.

(g) As shown in the illustration, measure the 2 places of the transaxle housing. Calculate the dimension E using the formula.
NOTE: Note down the dimension E as it is necessary for the following process.
HINT: Dimension E = Dimension (1) - Dimension (2)

30. INSPECT MULTIPLE DISC CLUTCH CLUTCH HUB Transaxle Unit

31. INSTALL MULTIPLE DISC CLUTCH CLUTCH HUB

(a) Install the bearing race to the transaxle while checking its direction.
Standard bearing diameter:

(b) Coat the thrust needle roller bearing and race with petroleum jelly, and install them onto the multiple disc clutch hub.
Standard thrust bearing and race diameter:

(d) Install the forward clutch hub to the transaxle.
32. INSTALL FORWARD CLUTCH ASSEMBLY

(a) Install the input shaft thrust bearing to the forward clutch.
Standard bearing diameter:

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

(b) Install the forward clutch to the multiple clutch hub.
NOTE: Align the splines of all discs in the forward clutch with those of multiple clutch hub to assemble them securely.

33. INSTALL OVERDRIVE BRAKE GASKET

(a) Install 2 new overdrive brake gaskets to the transaxle.
34. INSTALL FRONT DIFFERENTIAL ASSEMBLY

(a) Install the differential assembly to the transaxle.
35. INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE

(a) Install the thrust bearing race to the underdrive planetary gear.
36. INSTALL THRUST NEEDLE ROLLER BEARING

(a) Calculate the end play value using the following formula and value of Dimensions D and E that were measured when installing the cylindrical roller bearing and underdrive planetary gear. Select an appropriate underdrive planetary gear thrust bearing race No. 2 which satisfies the specified end play value, and install it.
Standard end play:
0.498 to 0.993 mm (0.0194 to 0.0390 in.)
HINT: End play = Dimension E - Dimension D - thrust bearing thickness 3.28 mm (0.1291 in.) - underdrive thrust bearing race thickness.

Standard race thickness:
Standard bearing and bearing race diameter

37. INSTALL OIL PUMP ASSEMBLY

(a) Install the oil pump to the transaxle with the 7 bolts.
Torque: 22 Nm (226 kgf-cm, 16 ft-lbf)
38. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING

(a) Install a new oil seal ring to the transaxle housing.
39. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING

(a) Using SST and a press, press in the underdrive cylindrical roller bearing.
SST: 09950-60020
SST: 09950-70010
09951-07100
09951-07100
NOTE: Do not apply excessive pressure to it.

40. INSTALL TRANSAXLE HOUSING

(a) Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle case or transaxle housing.
(b) Apply seal packing to the transaxle case.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(c) Install the transaxle housing and to the transaxle with the 16 bolts.
Torque: 22 Nm (224 kgf-cm, 16 ft-lbf)
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
HINT: Each bolt length is indicated below.

Bolt length:
50 mm (1.969 in.) for bolt A
50 mm (1.969 in.) for bolt B
42 mm (1.654 in.) for bolt C
NOTE: Because the bolt A is a seal bolt, apply the seal packing to new bolts and tighten them within 10 minutes after application.

Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
41. INSTALL NO. 1 TRANSAXLE CASE PLUG

(a) Install 2 new O-rings to the 2 plugs.
(b) Install the 2 plugs to the transaxle housing.
Torque: 7.4 Nm (75 kgf-cm, 65 in-lbf)
42. INSPECT INPUT SHAFT END PLAY Transaxle Unit

43. FIX AUTOMATIC TRANSAXLE ASSEMBLY
44. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

(a) Coat a new oil seal with ATF, and install it to the transaxle.
(b) Install the oil seal to the transaxle.
45. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

(a) Install the parking lock rod to the manual valve lever.
46. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

(a) Install a new spacer and manual valve lever shaft to the transaxle.

(b) Using a pin punch and hammer, tap in a new pin.

(c) Turn the spacer and lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.
(d) Using a pin punch, stake the spacer through the small hole.
(e) Check that the spacer does not turn.
47. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING

(a) Using needle-nose pliers, install the retainer spring.
48. INSTALL PARKING LOCK PAWL BRACKET

(a) Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
Bolt length:
25 mm (0.984 in.)
49. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY

(a) Install the manual detent spring with the 2 bolts.
NOTE: Make sure to install the manual detent spring and cover in this order.

Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
HINT: Each bolt length is indicated below.

Bolt length:
27 mm (1.063 in.) for bolt A
16 mm (0.630 in.) for bolt B
50. INSTALL B-3 ACCUMULATOR PISTON

(a) Coat a new O-ring with ATF, and install it to the B-3 accumulator piston.

(b) Coat the accumulator B-3 piston and spring with ATF, and install them to the transaxle.
Standard accumulator spring:

51. INSTALL C-1 ACCUMULATOR PISTON

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

(b) Coat the accumulator C-1 piston with ATF, and install it to the transaxle.
Standard accumulator spring:

52. INSTALL C-3 ACCUMULATOR PISTON

(a) Coat a new O-ring with ATF, and install it to the C-3 accumulator piston.

(b) Coat the C-3 accumulator piston with ATF, and install it to the transaxle.

(a) Install the check ball body and spring.
54. INSTALL TRANSMISSION WIRE

(a) Coat a new O-ring with ATF, and install it to the transaxle solenoid wire.

(b) Install the solenoid wire retaining bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
55. INSTALL BRAKE DRUM GASKET

(a) Coat a new brake drum gasket with ATF, and install it to the transaxle.
56. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET

(a) Coat a new transaxle case 2nd brake gasket with ATF, and install it to the transaxle.
57. INSTALL NO. 1 GOVERNOR APPLY GASKET

(a) Coat a new governor apply gasket No. 1 with ATF, and install it to the transaxle.
58. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

(a) Make sure that the manual valve lever position, install the valve body with the 17 bolts to the transaxle.
Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
HINT: Each bolt length is indicated below.

Bolt length:
25 mm (0.984 in.) for bolt A
41 mm (1.614 in.) for bolt B
45 mm (1.771 in.) for bolt C
- Push the valve body against the accumulator piston spring and the check ball body to install it.
- When installing the valve body to the transaxle case, do not hold the solenoids.
- Tighten the bolts marked by * in the illustration first temporarily because they are positioning bolts.

(b) Connect the 5 solenoid connectors.
(c) Install the ATF temperature sensor, clamp and bolt.
Torque: 6.6 Nm (67 kgf-cm, 58 in-lbf)