Part 1

U151E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY

1. BEARING POSITION

Standard bearing position:

2. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE

(a) Install the differential gear lube apply tube and transaxle 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 pipe to the stopper.

3. 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)
4. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING

(a) Coat a new oil seal ring with ATF and install it to the transaxle housing.
5. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING

(a) Coat the underdrive cylindrical roller bearing with ATF.
(b) Using SST and a press, press in the underdrive cylindrical roller bearing.
SST: 09950-60020
09951-00810
SST: 09950-70010
09951-07100
NOTE: Do not apply excessive pressure to the bearing.

6. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING

(a) Coat 2 new oil seal rings with ATF, and install them to the transaxle rear cover.
- Do not expand the end gap of the oil seal ring too much.
- Fix the hooks firmly. Confirm that the oil seal ring rotates freely in its groove.

7. INSTALL NEEDLE ROLLER BEARING

(a) Wrap vinyl tape around SST 4.0 mm (0.157 in.) from the bottom of SST until the thickness of the tape is about 5.0 mm (0.197 in.).
SST: 09950-60010
09951-00320
SST: 09950-70010
09951-07100
NOTE: Clean SST to remove deposited oil before wrapping vinyl tape.

(b) Coat the needle roller bearing with ATF.

(c) Using SST and a press, press in the needle-roller bearing to the transaxle case.
SST: 09950-60010
09951-00320
SST: 09950-70010
09951-07100
NOTE: When the wrapped vinyl tape contacts the transaxle case, stop press-fitting.

8. INSTALL UNDERDRIVE BRAKE PISTON

(a) Coat 2 new O-rings with ATF, and install them to the underdrive brake piston.
- Make sure that the O-rings are not twisted or pinched when they are installed.
- Apply sufficient ATF to the O-ring before installing.

(b) Coat the underdrive brake piston with ATF.

(c) Install the underdrive brake piston to the transaxle case.
NOTE: Be careful not to damage the O-ring.

9. INSTALL UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY

(a) Place SST on the return spring and compress the return spring with a press.
- Stop the press when the spring seat is lowered to a position 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from being deformed.
- After installing the return spring, check that all the return spring's springs fit in the piston correctly.

SST: 09387-00020
(b) Using a snap ring expander, press in the snap ring to the transaxle case.
NOTE: The snap ring must be fully engaged in the groove of the transaxle case.

10. INSTALL NO. 2 BREATHER PLUG
11. INSTALL COUNTER DRIVE GEAR BEARING

(a) Coat the counter drive gear bearing with ATF.
(b) Using SST and a press, press in the bearing outer race.
SST: 09950-60020
09951-01030
SST: 09950-70010
09951-07150
SST: 09649-17010
NOTICE:
- Do not apply excessive pressure to the bearing.
- Press-fit the bearing outer race until it contacts the transaxle case.

(c) Using a snap ring expander, install the snap ring.
NOTE: The white mark side of the snap ring should face upward.

12. INSTALL COUNTER DRIVE GEAR

(a) Coat the counter drive gear with ATF.
(b) Using SST and a press, press in the tapered roller bearing to the counter drive gear.
SST: 09950-70010
09951-07150
SST: 09649-17010
NOTE: Do not apply excessive pressure to the bearing.

(c) Using SST and a press, press in the counter drive gear and bearing to the transaxle case.
SST: 09950-70010
09951-07150
SST: 09223-15030
SST: 09527-17011
SST: 09950-60020
09951-00750
NOTE: Do not apply excessive pressure to the counter drive gear.

13. INSTALL 1ST AND REVERSE BRAKE PISTON

(a) Coat 2 new O-rings with ATF.
(b) Install the 2 O-rings to the 1st and reverse brake piston.
NOTICE:
- Make sure that the O-rings are not twisted or pinched when they are installed.
- Apply sufficient ATF to the O-ring prior to assembling.

(c) Coat the 1st and reverse brake piston with ATF, and install it to the transaxle case.
NOTE: Be careful not to damage the O-ring.

14. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

(a) Place SST on the return spring and compress the return spring with a press.
- Stop the press when the spring seat is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from being deformed.
- After installing the return spring, check that all the return spring's springs fit in the piston correctly.

SST: 09387-00070
(b) Using a snap ring expander, press in the snap ring to the transaxle case.
NOTICE:
- The snap ring must be fully engaged in the groove of the transaxle case.
- Fix the snap ring to the inside of the claw of the spring seat firmly.

15. INSTALL FRONT PLANETARY RING GEAR

(a) Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.
NOTE: Confirm that the snap ring is engaged in the groove of the brake hub correctly.

16. 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.
SST: 09950-60010
09951-00500
SST: 09950-70010
09951-07100
- Do not apply excessive pressure to the planetary gear.
- Press the inner race of the LH tapered roller bearing, counter gear and front planetary gear to the position where no preload should be applied to one pair of tapered roller bearings (left and right).

(d) Using SST, install the nut.
SST: 09387-00030
SST: 09387-00080
Torque: 280 Nm (2,855 kgf-cm, 207 ft-lbf)
NOTE: Assemble the washer after pressing each part, then tighten the nut to the standard torque.

(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 as specified, gradually tighten the nut until it reaches the specified value.
SST: 09387-00080
Standard turning torque at 60 rpm:
0.51 to 1.02 N*m (5.1 to 10.0 kgf*cm, 4.4 to 8.7 in.*lbf) for new bearing
0.26 to 0.51 N*m (2.7 to 5.2 kgf*cm, 2.3 to 4.5 in.*lbf) for used bearing
(f) Tighten the nut gradually until the specified turning torque of the tapered roller bearing is measured.
Torque: 350 Nm (3,569 kgf-cm, 258 ft-lbf)

(g) Using a chisel and hammer, stake the front lock washer.
17. INSTALL INPUT SUN GEAR

(a) Coat the 2 thrust bearings with ATF.
(b) Install the 2 thrust bearings, bearing race and input sun gear to the front planetary gear.
NOTICE:
- Install the bearing race on the side of the front planetary carrier. Be careful about the direction of the race.
- When installing the thrust bearing and front sun gears, be careful about the direction of the parts.
- When install the bearing race on the side of the front sun gear, be careful of the direction of the race.
- Install the thrust bearing and the race after holding the parts on the input sun gear by applying grease. Make sure that the assembling order is correct.

Standard thrust bearing and bearing race diameter:

18. INSTALL REAR PLANETARY GEAR ASSEMBLY

(a) Install the rear planetary gear to the rear planetary ring gear.

(b) Using a screwdriver, install the snap ring.
NOTE: Confirm that the snap ring is fixed in the groove of the 1st and reverse brake hub correctly.

19. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC

(a) Coat the 6 discs with the ATF.
(b) Install the 6 plates and 6 discs.
NOTE: Make sure that the plates and discs are installed as shown in the illustration.

20. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE

(a) Using a vernier caliper, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case (Dimension A).
(b) Select an appropriate flange so that the pack clearance will meet the specified value.
Standard pack clearance:
1.16 to 1.35 mm (0.0457 to 0.0531 in.)
HINT: Piston stroke = Dimension A - Flange thickness

Standard flange thickness:

(a) Install the second brake piston to the transaxle case.

(b) Install the snap ring and measure the inside diameter.
Inside diameter:
Greater than 167 mm (6.57 in.)
- Make sure that the taper snap ring is installed in the correct direction.
- When the diameter does not meet the specified value, replace the snap ring with a new one.
- After installing the snap ring, confirm that there is no clearance between the 2nd brake cylinder and the fitting surface of the cylinder in the transaxle case.

22. INSTALL 1-WAY CLUTCH SLEEVE OUTER

(a) Install the 1-way clutch sleeve outer to the 2nd brake cylinder.
NOTE: Make sure that the outer sleeve is installed in the correct direction.

23. INSTALL 1-WAY CLUTCH ASSEMBLY

(a) Install the 1-way clutch inner race to the 1-way clutch.
- Make sure that the inner race is installed in the correct direction.
- Confirm that the discrimination mark is visible.

(b) Check that the 1-way clutch locks when turned clockwise and rotates freely when turned counterclockwise as shown in the illustration.
If the result is not as specified, replace the 1-way clutch.

(c) Install the 1-way clutch and thrust needle roller bearing to the 1-way clutch sleeve outer.
Standard bearing diameter:

NOTE: Install the thrust bearing properly so that the non-colored race will be visible.

24. INSTALL NO. 1 PLANETARY CARRIER THRUST WASHER

(a) Coat the planetary carrier thrust washer with yellow petrolatum, and install the washer onto the planetary sun gear.
NOTE: After installing the washer, confirm that the projection of the washer is fixed firmly in the hole of the planetary sun gear.

25. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY

(a) Coat the planetary carrier thrust washer with yellow petrolatum, and install the washer onto the rear planetary sun gear.

(b) Coat the bearing with yellow petrolatum, and install the bearing onto the rear planetary sun gear.
Standard bearing diameter:

(c) Install the rear planetary sun gear to the rear planetary gear.
NOTE: After installing the rear planetary sun gear, make sure that the B1 discs are engaged.

26. INSTALL 2ND BRAKE CLUTCH DISC

(a) Coat the 4 discs with ATF.
(b) Install the 4 plates and 4 discs to the transaxle case.
NOTE: Make sure that the plates and discs are installed as shown in the illustration.

(c) Temporarily install the snap ring.
27. INSPECT PACK CLEARANCE OF 2ND BRAKE

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

Standard flange thickness:

(c) Temporarily remove the snap ring, attach the selected flange and reinstall the snap ring.
NOTE: Secure the snap ring so that the ends are visible through the groove of the transaxle case.

28. INSTALL OVERDRIVE DIRECT CLUTCH HUB SUB-ASSEMBLY

(a) Install the direct clutch hub to the planetary gear.
NOTE: Be careful not to damage the bushing inside the overdrive clutch hub during installation.

(b) Coat the thrust bearing with ATF.
(c) Install the bearing race and the thrust bearing to the direct clutch hub.
NOTE: Be careful not to drop the bearing when it is installed.

Standard bearing and race diameter:

29. INSTALL DIRECT CLUTCH ASSEMBLY

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

(c) Clean the connecting part of the transaxle case and the 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 C).

(e) Using a vernier caliper and straightedge, measure the dimension shown in the illustration (Dimension D).
(f) Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install the selected bearing.
Standard end play:
0.244 to 0.901 mm (0.0096 to 0.0355 in.)
NOTE: Make sure that the non-collared race side is facing the direct clutch.
HINT: End play = Dimension D - Dimension C

Standard bearing thickness and diameter:

30. INSTALL NO. 1 GOVERNOR APPLY GASKET

(a) Install 3 new governor apply gaskets to the transaxle case.
31. INSTALL BRAKE APPLY TUBE
(a) Install the clamp to the brake apply tube.
NOTE: Make sure to install the clamp to the apply tube before installing the apply tube to the transaxle case. This prevents the apply tube from being deformed or damaged.

(b) Install the clutch apply tube.

(c) Install the brake apply tube to the transaxle case with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
NOTE: The tube should be securely inserted until it reaches the stopper.

32. INSTALL NEEDLE ROLLER BEARING

(a) Using SST and a press, press the needle roller bearing into the transaxle rear cover.
SST: 09950-60010
09951-00230
09952-06010
Standard depth:
20.55 to 21.25 mm (0.8091 to 0.8366 in.)
- The engraved mark side of the bearing should face upward.
- Continue pressing until the specified value is obtained.

(b) Coat a needle roller bearing with ATF.
33. INSTALL REAR CLUTCH OIL SEAL RING OUTER

(a) Coat 3 new rear clutch oil seal rings with ATF, and install them to the transaxle rear cover.
NOTE: The snap ring should be fully engaged in the groove of the drum.

34. INSTALL NO. 1 TRANSAXLE CASE PLUG

(a) Coat 4 new O-rings with ATF.
(b) Install the 4 O-rings to the 4 plugs.
(c) Install the 4 plugs to the transaxle rear cover.
Torque: 7.4 Nm (75 kgf-cm, 65 in-lbf)
35. INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY

(a) Remove any packing material and be careful not to spill oil on the contact surfaces of the transaxle rear cover or the transaxle case.
(b) Apply FIPG to the cover.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
NOTE: Make sure that the seal packing is applied in a bead (section diameter: dia1.2 mm (0.047 in.)) so that the entire sealing surface will be evenly sealed. The seal packing should also protrude slightly from the flange after the installation of the cover has been completed.

(c) Apply adhesive to the threads of bolt A.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(d) Install the cover with 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 bolts
36. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC

(a) Coat the 4 discs with ATF.
(b) Install the 4 discs, 4 plates and flange to the transaxle case.
NOTE: Be careful of the order of the discs, plate and flange.

(c) Using a screwdriver, install the snap ring.
NOTE: The snap ring should be fully engaged in the groove of the drum.